MA-5002VZ Service Manual

POWER AMPLIFIER

SERVICE MANUAL

130446-102-00Rev. A

Macro-Tech®

© 2000 by Crown International, Inc., P.O. Box 1000, Elkhart, Indiana 46515-1000 U.S.A.Telephone: 219-294-8000. Trademark Notice: Grounded Bridge™, PIP2™ and SmartAmp™ aretrademarks and Amcron®, Crown®, IOC®, IQ System®, Macro-Tech,® ODEP® and VZ® areregistered trademarks of Crown International, Inc. Other trademarks are the property of theirrespective owners.

Models:MA-5002VZ

Some models may be exported under the name Amcron®

MA-5002VZ Service Manual

II

130446-1 Rev. A

©2000 Crown International, Inc.

À PRÉVENIR LE CHOCÉLECTRIQUE N’ENLEVEZPAS LES COUVERTURES.

RIEN DES PARTIESUTILES À L’INTÉRIEUR.

DÉBRANCHER LA BORNEAVANT D’OUVRIR LA

MODULE EN ARRIÈRE.

TO PREVENT ELECTRIC SHOCK DONOT REMOVE TOP OR BOTTOM

COVERS. NO USER SERVICEABLEPARTS INSIDE. REFER SERVICING

TO QUALIFIED SERVICEPERSONNEL. DISCONNECT

POWER CORD BEFORE REMOVINGREAR INPUT MODULE TO ACCESS

GAIN SWITCH.

CAUTION AVIS

WARNINGTO REDUCE THE RISK OF ELECTRIC

SHOCK, DO NOT EXPOSE THISEQUIPMENT TO RAIN OR MOISTURE!

The information furnished in this manual does not include all of the details of design, production, or variationsof the equipment. Nor does it cover every possible situation which may arise during installation, operation ormaintenance. If you need special assistance beyond the scope of this manual, please contact the CrownTechnical Support Group.

Mail: P.O. Box 1000 Elkhart IN 46515-1000Shipping: Plant 2 SW 1718 W. Mishawaka Road Elkhart IN 46517

Phone: (800) 342-6939 / (219) 294-8200FAX: (219) 294-8301

The lightning bolttriangle is used toalert the user to therisk of electric shock.

The exclamation pointtriangle is used to alert theuser to important operatingor maintenance instructions.

III

130446-1 Rev. A MA-5002VZ Service Manual


Revision History

Revision Number Date Comments

Rev. A 02-2000 Initial Printing


IV

130446-1 Rev. A


This page intentionally left blank

V



Table of Contents1 Introduction ............................................................................ 1-1

1.1 Introduction ................................................................................ 1-11.2 The MA “02” Series Amplifiers ................................................... 1-11.3 Scope ......................................................................................... 1-11.4 Warranty ..................................................................................... 1-1

2 Specifications ......................................................................... 2-1

3 Voltage Conversion ................................................................ 3-1

4 Circuit Theory ........................................................................ 4-14.1 Overview .................................................................................... 4-14.2 Grounded Bridge Theory ........................................................... 4-1

4.2.1 Grounded Bridge Operation ............................................. 4-24.2.2 Output Stage Circuitry ....................................................... 4-3

4.3 VZ Power Supply ........................................................................ 4-44.3.1 VZ Supply Operation ......................................................... 4-44.3.2 VZ Supply Circuitry ........................................................... 4-5

4.4 ODEP Theory ............................................................................. 4-64.4.1 ODEP Operation ................................................................ 4-64.4.2 ODEP Circuitry .................................................................. 4-7

4.5 Front End Theory ........................................................................ 4-84.5.1 Balanced Gain Stage ........................................................ 4-84.5.2 Variable Gain Stage .......................................................... 4-84.5.3 Error Amp .......................................................................... 4-84.5.4 Compessor ........................................................................ 4-94.5.5 Loudspeaker Offset Integration ........................................ 4-94.5.6 Voltage Translator and LVA Stages .................................. 4-94.5.7 Inverting Stages ................................................................ 4-9

4.6 Protection Systems .................................................................... 4-94.6.1 Soft Start ............................................................................ 4-94.6.2 Over-voltage.................................................................... 4-114.6.3 DC/LF .............................................................................. 4-114.6.4 Commom Mode Output Current ...................................... 4-124.6.5 Output Thermal ............................................................... 4-124.6.6 Transformer Thermal ....................................................... 4-124.6.7 FET Thermal .................................................................... 4-124.6.8 Power Loss ...................................................................... 4-134.6.9 Fan Control ...................................................................... 4-13

4.7 Display ..................................................................................... 4-134.8 Mono Modes ............................................................................ 4-13

4.8.1 Bridge Mono.................................................................... 4-134.8.2 Parallel Mono................................................................... 4-14


VI

130446-1 Rev. A


5 Maintenance........................................................................... 5-15.1 Cautions and Warnings .............................................................. 5-15.2 General Information ................................................................... 5-15.3 Troubleshooting ........................................................................ 5-1

5.3.1 Pre-AC-Checks ................................................................ 5-15.3.2 LED Checks ..................................................................... 5-2

5.4 Test Procedures ......................................................................... 5-45.4.1 Standard Initial Conditions ................................................ 5-45.4.2 Equipment Required ......................................................... 5-4

6 Parts ....................................................................................... 6-16.1 General Information .................................................................. 6-16.2 Ordering and Receiving Parts .................................................. 6-16.2.1 Terms ..................................................................................... 6-16.2.2 Shipment ................................................................................ 6-1

7 Exploded View Parts ............................................................ 7 -1

8 Module and Schematic Information .................................... 8 -1

9 Module Parts .......................................................................... 9-1

10 Schematics ........................................................................ 10-1

Table of Contents

Introduction 1-1



1.1 IntroductionThis manual contains complete service information onthe Crown® MA-5002VZ power amplifier. It is designedto be used in conjunction with the Reference Manual;however, some important information is duplicated inthis Service Manual in case the Reference Manual isnot readily available.

NOTE: THE INFORMATION IN THIS MANUAL ISINTENDED FOR USE BY AN EXPERIENCED TECH-NICIAN ONLY!

1.2 The MA “02” Series AmplifiersThe Macro-Tech® series is a complete family of ampli-fiers designed for pro sound reinforcement. Macro-Tech amplifiers are designed to provide enormous lev-els of pure, undistorted power in a rugged low-profilepackage, utilizing Crown's patented GroundedBridge™ output topology. They also employ Crown'spatented ODEP® protection circuitry, which keeps theamplifier working under extreme conditions that wouldshut down a lesser amplifier. Crown's new Macro-Tech“02” series amplifiers feature Crown's enhancedPIP2™ (Programmable Input Processor) expansionsystem. The PIP2 expansion system makes it easy totailor the amplifier to a specific application. Providinghigh power amplification from 20 Hz to 20 kHz withminimum distortion, Macro-Tech series amplifiers fea-ture balanced inputs with bridged and parallel mono-

phonic capability. The MA-5002VZ includes additionalfeatures not found on other Macro-Tech series modelsincluding switchable compression, switchable loud-speaker offset integration (LOI), and ILOAD/ILIMIT indi-cation.

1.3 ScopeThis Service Manual in intended to apply to all ver-sions of the MA-5002VZ amplifier. The Parts Listingsinclude parts specific for the US version and the Euro-pean version (E13). For parts specific only to otherversions contact the Crown Technical Support Groupfor help in finding part numbers.

1.4 WarrantyEach Reference Manual contains basic policies as re-lated to the customer. In addition, it should be statedthat this service documentation is meant to be usedonly by properly trained personnel. Because mostCrown products carry a 3-Year Full Warranty (includ-ing round trip shipping within the United States), allwarranty service should be referred to the Crown Fac-tory or Authorized Warranty Service Center. See theapplicable Reference Manual for warranty details. Tofind the location of the nearest Authorized WarrantyService Center or to obtain instructions for receivingCrown Factory Service, please contact the Crown Tech-nical Support Group (within North America), or yourCrown/Amcron Importer (outside North America). If youare an Authorized Warranty Service Center and havequestions regarding the warranty of a product, pleasecontact the Field Service Manager or the TechnicalSupport Group.

Crown Customer ServiceTechnical Support Group

Factory ServiceParts Department

Mailing Address: P.O. Box 1000, Elkhart IN 46515Shipping Address: Plant 2 S. W.

1718 W. Mishawaka Rd., Elkhart IN 46517Phone: (219) 294-8200

Toll Free: (800) 342-6939Fax: (219) 294-8301

http://www.crownaudio.com

1 Introduction


1-2 Introduction

130446-1 Rev. A


Figure 1.1 MA-5002VZ Front and Rear Views

Specifications 2-1



SpecificationsThe following applies to 120-VAC, 60-Hz units in Stereo mode with 8-ohm loads and aninput sensitivity of 26-dB gain unless otherwise specified. Specifications for unitssupplied outside the U.S.A. may vary slightly at different AC voltages and frequencies.

PowerOutput Power

Load Impedance: Safe with all types of loads. Rated for 2 to 8ohms in Stereo, 4 to 16 ohms in Bridge-Mono and 1 to 4 ohms inParallel-Mono mode.

Voltage Gain to 1-kHz, 8-ohm rated output:132:1 ±12% or 42 dB ±1 dB gain at 0.775 volt sensitivity;71:1 ±12% or 37 dB ±1 dB gain at 1.4-volt sensitivity; 20:1 ±3% or 26 dB ±0.25 dB gain at the maximum level setting.Required AC Mains: 50 or 60 Hz; 100-, 120-, 200-, 208-, 230-,240- VAC (±10%).

AC Line Current,

Current, voltage and frequency requirements are provided on theunit’s back panel.

At Idle: All units draw 90 watts or less.

AC Line Connector: 10 AWG cordset with NEMA TT30P plug isprovided on 120-VAC, 60-Hz North American units.

PerformanceFrequency Response: ±0.1 dB from 20 Hz to 20 kHz at 1 watt (seeFigure 2.3).

Phase Response: ±10 degrees from 10 Hz to 20 kHz at 1 watt (seeFigure 2.2).

Signal-to-Noise Ratio,A-weighted:

Better than 105 dB below rated 1-kHz power.

Total Harmonic Distortion (THD): 1-kHz rated power, 0.05% orless true THD.

Intermodulation Distortion (IMD): (60 Hz and 7 kHz at 4:1) Lessthan 0.05% from rated power to 35 dB below rated power at 8ohms.

Damping Factor: Greater than 1,000 from 10 Hz to 400 Hz (seeFigure 2.4).

Controlled Slew Rate: (Slew rates are limited to useful levels forultrasonic/RF protection.) Greater than 30 volts per microsecond.

ControlsCompressor: A three-position back-panel switch is used to controleach channel’s input compressor. The “fast” setting provides anattack time of 4 milliseconds and a release time of 300 millisec-onds; the “slow” setting provides an attack time of 12 millisecondsand a release time of 600 milliseconds; the “off” setting defeatsoutput-driven compression.

Enable: A front-panel push button used to turn the amplifier on andoff.

Input Ground Lift: A two-position back-panel switch located on thePIP2-FXQ used to isolate the input audio signal grounds from theAC (chassis) ground.

Level: A front-panel rotary potentiometer for each channel with 31detents used to control the output level.

Loudspeaker Offset Integration: A two-position back-panel switchfor each channel used to turn the loudspeaker protection circuitryon and off. The circuitry protects against DC, off-center woofercone movement, and unwanted subsonic and ultrasonic frequen-cies.

Sensitivity: A three-position back-panel switch for each channelused to select input sensitivity: 0.775 volts or 1.4 volts forstandard 1-kHz power, or a 26 dB voltage gain.

Stereo/Mono: A three-position back-panel switch used to selectStereo, Bridge-Mono or Parallel-Mono mode.

VZ Mode: A four-position switch for each channel inside the front-panel used to control the switching mode of the VZ power supplies.

IndicatorsEnable: An amber front-panel LED that shows the on/off status ofthe low-voltage power supply.

Signal/IOC: A green front-panel LED for each channel that flashesto show amplifier output. If a channel’s output waveform differsfrom its input by 0.05% or more, the indicator flashes brightly toshow distortion.

ODEP: An amber front-panel LED for each channel that showsthermal-dynamic energy reserve. Normally, each ODEP indicator islit to show available reserve energy. In the rare event that a channelhas no reserve, its indicator will dim in proportion to ODEPlimiting.

ILoad/ILimit: A two-color (green/red) LED for each channel thatshows load current and limit current. They glow green to indicateload current flowing out the amplifier, and they turn red whenmaximum current is being delivered to the load.

Input/OutputInput Connectors: Balanced three-pin XLR and balanced ¼-inch(6.35-mm) TRS connectors are provided on the factory-installedPIP2-FXQ module.

Input Impedance: Greater than 10 ohms, balanced. Greater than 5ohms, unbalanced.

Input Sensitivity: Settings include 0.775 volts or 1.4 volts forstandard 1 kHz power, or a 26-dB voltage gain.

Output Connectors: A multifunction, high-current output block isprovided. Crown output blocks include three pairs of connectorsfor each channel (a total of 12 connectors). This allows multipleloudspeakers to be easily connected to each channel. High currentscrew terminals and banana jacks are provided which accept spadelugs, banana plugs or bare wire.

Output Impedance: Less than 10 milliohms in series with less than2.5 microhenries(see Figure 2.5).

2-ohm Dual (per ch.)

1 kHzPower

2,500W

2,000W1,300W

5,000W

4,000W

2,155W

1,775W1,090W

3,670W8-ohm Bridge-Mono

4-ohm Bridge-Mono



*1 kHz Power: refers to maximum average power in watts at 1 kHz with 0.1% THD.**20 Hz– 20 kHz Power: refers to maximum average power in watts from 20 Hz to 20 kHz with 0.1% THD.

MA-5002VZ * 20 Hz– 20 kHzPower

**

2 Specifications


2-2 Specifications

130446-1 Rev. A


Figure 2.1 Dimensions

DC Output Offset: ±10 millivolts.

Output SignalStereo: Unbalanced, two-channel.

Bridge-Mono: Balanced, single-channel. Channel 1 controls areactive; Channel 2 controls are removed from operation.

Parallel-Mono: Unbalanced, single-channel. Channel 1 controls areactive; Channel 2 controls are by passed.

ProtectionMacro-Tech amplifiers are protected against shorted, open ormismatched loads; overloaded power supplies; excessivetemperature; chain destruction phenomena; input overloaddamage; and high-frequency blowups.They also protect loud-speakers from input/output DC and turn-on/turn-off transients.

If unreasonable operating conditions occur, the patented ODEPcircuitry will proportionally limit the drive level to protect theoutput transistor stages, particularly in the case of elevatedtemperature. Transformer overheating will result in a temporaryshutdown of the affected channel; when it has cooled to a safetemperature, the transformer will automatically reset itself.Controlled slew rate voltage amplifiers protect against RF burnouts.

Figure 2.2 Typical Phase Response

And input overload protection is provided by the input compres-sors and current-limiting resistance at the input.

Turn On: The four second turn-on delay prevents dangerous turn-on transients. It also has “ soft start” to avoid tripping the AC circuitbreaker by gradually bringing the supplies up to full voltage.

Accessories: Crown PIP and PIP2 modules including IQ-PIPmodules.

ConstructionSteel chassis with durable black finish, aluminum front panel withLexan overlay, and specially designed flow-through ventilation fromfront to back panels.

Cooling: Internal heat sinks with on-demand, proportional forced-air cooling controlled by ODEP. Includes custom heat diffusers andpatented circuitry to promote uniform dissipation.

Dimensions: 19-inch (48.3-cm) standard rack mount width (EIARS-310-B), 5.2-inch (13.3-cm) height, 15.875-inch (40.3-cm)depth behind mounting surface, and 2.875 inches (7.3 cm) in frontof mounting surface (see Figure 2.1). Allow 3 inches (7.6 cm)behind the back panel for adequate air flow.

Approximate Weight: 77 pounds, 9 ounces (35.2 kg) net; 88pounds, 10 ounces (40.2 kg) shipping weight.

TEF ®

+45˚

0˚

–45˚

100 1 K 10 K 20 K

FREQUENCY (Hz)

Specifications 2-3



Figure 2.3 Typical Frequency Response

Figure 2.4 Typical Damping Factor

Figure 2.5 Typical Output Impedance


2-4 Specifications

130446-1 Rev. A



Voltage Conversion 3-1



3 Voltage ConversionINSTRUCTIONS

CAUTION: Because there is a risk ofelectric shock, only a qualified technician

should change the line voltage configuration.

1. Turn the amplifier off and disconnect it from the ACpower source. (The enable switch alone does not re-move lethal voltage from the line cord.) Wait at least 10seconds before proceeding.

2. Drain any remaining energy from the power suppliesby shorting them as follows: Touch a 100 ohm, 10 wattresistor across terminals A1 and A2 and across B1 andB2 as shown in the illustration. The resistor should beheld across the terminals for 10 seconds. Be careful—the resistor can become hot.

3. Locate the Control Board. It is the circuit board clos-est to the front of the amplifier. It contains numerouspower supply connections which set the voltage andone jumper block which sets the frequency.

4. Use the information in Figure 3.1 to connect the color-coded wiring harness correctly for the desired voltage.Configure each wire group one at a time so the wiresare not confused. Do not mix wires between groups.This step may require you to cut one or more tie wraps.If you do, replace them to make sure no loose wires areable to prevent the fans from rotating.

5. Locate the frequency jumper (JP1) and set it for ei-ther 60 Hz (left) or 50 Hz (right).

6. Locate the fan connector (P729/P730) and move it tothe appropriate voltage connector (left for 200-240 VACor right for 100-120 VAC).

7. Double check that all connections are correct andreplace the top cover.

The MA-5002VZ power amplifier may easily be con-verted to a variety of AC mains voltages and may oper-ate at 50 or 60 Hz. Complete directions to accomplishline voltage and/or frequency changes are found on alabel under the top cover of the unit. For conveniencethis information is duplicated here and on the followingpage.

NO.**

P712

P711

P724B

P707

P704

P705

P710

P709

P708

P703

P701

P700

P702

P713

P714

P722

P749

P750

P718

P716

P721

P719

P715

P724A

P736

P735

P734

P742

P737

P744

P743

P738

P739

P745

P724C

P741

P740

P729*** P730***

100 V

BLK

WHT

BLU*

BLK/GRN

--NONE--

--NONE--

WHT/GRN

WHT/RED

WHT/YEL

BLK/YEL

GRY

GRY

GRN/YEL

BLK/YEL

WHT/YEL

BRN*

WHT/RED

WHT/GRN

--NONE--

--NONE--

BLK/GRN

BLK

WHT

BLU*

GRN/YEL

GRY

GRY

BLK/YEL

WHT/YEL

WHT/RED

WHT/GRN

--NONE--

--NONE--

BLK/GRN

BLU*

WHT

BLK

BLK

WHT

BLU*

BLK/YEL

--NONE--

--NONE--

WHT/YEL

WHT/RED

WHT/GRN

BLK/GRN

GRY

GRY

GRN/YEL

BLK/GRN

WHT/GRN

BRN*

WHT/RED

WHT/YEL

--NONE--

--NONE--

BLK/YEL

BLK

WHT

BLU*

GRN/YEL

GRY

GRY

BLK/GRN

WHT/GRN

WHT/RED

WHT/YEL

--NONE--

--NONE--

BLK/YEL

BLU*

WHT

BLK

BLK

--NONE--

BLU*

BLK/GRN

BLK/YEL

WHT

WHT/RED

WHT/GRN

WHT/YEL

--NONE--

GRY

GRY

GRN/YEL

--NONE--

WHT/YEL

BRN*

WHT/GRN

WHT/RED

WHT

BLK/YEL

BLK/GRN

BLK

--NONE--

BLU*

GRN/YEL

GRY

GRY

--NONE--

WHT/YEL

WHT/GRN

WHT/RED

WHT

BLK/YEL

BLK/GRN

BLU*

--NONE--

BLK

BLK

--NONE--

BLU*

BLK/GRN

BLK/YEL

WHT

WHT/YEL

WHT/GRN

WHT/RED

--NONE--

GRY

GRY

GRN/YEL

--NONE--

WHT/RED

BRN*

WHT/GRN

WHT/RED

WHT

BLK/YEL

BLK/GRN

BLK

--NONE--

BLU*

GRN/YEL

GRY

GRY

--NONE--

WHT/RED

WHT/GRN

WHT/YEL

WHT

BLK/YEL

BLK/GRN

BLU*

--NONE--

BLK

BLK

--NONE--

BLU*

BLK/YEL

WHT

BLK/GRN

WHT/YEL

WHT/GRN

WHT/RED

--NONE--

GRY

GRY

GRN/YEL

--NONE--

WHT/RED

BRN*

WHT/GRN

WHT/YEL

BLK/GRN

WHT

BLK/YEL

BLK

--NONE--

BLU*

GRN/YEL

GRY

GRY

--NONE--

WHT/RED

WHT/GRN

WHT/YEL

BLK/GRN

WHT

BLK/YEL

BLU*

--NONE--

BLK

BLK

--NONE--

BLU*

BLK/YEL

WHT

BLK/GRN

WHT/YEL

WHT/RED

WHT/GRN

--NONE--

GRY

GRY

GRN/YEL

--NONE--

WHT/GRN

BRN*

WHT/RED

WHT/YEL

BLK/GRN

WHT

BLK/YEL

BLK

--NONE--

BLU*

GRN/YEL

GRY

GRY

--NONE--

WHT/GRN

WHT/RED

WHT/YEL

BLK/GRN

WHT

BLK/YEL

BLU*

--NONE--

BLK

120 V 200 V 208 V 230 V 240 V

Control Board Wiring for Different AC Voltages

120 V Position 240 V Position

Figure 3.1 Voltage/Frequency Conversion Chart

* Wire colors marked with a single asterisk connect to the power cord.

** The connector numbers are listed in clockwise order from left to rightas you face the front of the amplifier.

*** Connection P729 and P730 are combined on a single four-pin connec-tor. It mates to a “120V” connector for 100V or 120V operation or a“240V” connector for 200, 208, 230 or 240 volts.


3-2 Voltage Conversion

130446-1 Rev. A


CAUTION: To reduce the risk of fire,replace F700, F701, & F702 with thesame type fuse. Use a 30 A fuse for F700& F701 and a 1A fuse for F701 for ALLvoltage configurations.

ATTENTION: Utiliser un fusible de mêmetype (F700, F701 = 30A. F702 = 1A.)pour toutes applications.

Figure 3.2 Voltage/Frequency Conversion Physical Layout

Circuit Theory 4-1



4 Circuit Theory

4.1 OverviewIt should be noted that over time Crown makes improve-ments and changes to their products for various rea-sons. This manual is up to date as of the time of writing.For additional information regarding these amplifiers,refer to the applicable Technical Notes provided byCrown for this product. Sketches have been added tothis section for clarification of the various concepts pre-sented, as well as block diagrams for the amplifier andspecific portions of the amplifier. For detailed schemat-ics refer to Section 6.

The Macro-Tech 5002VZ amplifier incorporates severalnew technological advancements, including real-timecomputer simulation of output transistor stress, low-stress output stages, an advanced heat diffuser em-bodiment, a programmable input processor (PIP) ex-pansion system, and articulated VZ power supplies.

Custom circuitry is incorporated to limit temperature andcurrent to safe levels—making it highly reliable and tol-erant of faults. Unlike many lesser amplifiers, the Macro-Tech 5002VZ can operate at its voltage and current lim-its without self-destructing.

Real-time computer simulation is used to create an ana-log reading of the junction temperature of the outputtransistors (herein referred to as the output devices).Current is limited only when the device temperature be-comes excessive—and just by the minimum amountnecessary. This patented approach, called ODEP (Out-put Device Emulation Protection) maximizes the avail-able output power and eliminates overheating—themajor cause of device failure. ODEP in the MA-5002VZalso provides indication of amplifier thermal reserve(front panel ODEP indicators) and may provide controlof VZ mode when the VZ mode select switches areplaced in the VZ-ODEP position.

The amplifier is protected from all common hazards thatplague high-power amplifiers, including shorted, openor mismatched loads, overloaded power supplies, ex-cessive temperature, chain-destruction phenomena,input-overload damage, and high-frequency blowups.The unit protects loudspeakers from DC in the inputsignal and from turn-on and turn-off transients. It alsodetects and prevents unwanted DC on the outputs.Additional protection features include input voltagesense as well as overvoltage (AC mains).

A mode of protection which may be switched on or off

is called Loudspeaker Offset Integration (LOI). The LOIcircuit, when switched on, prevents excessive bass fre-quency cone excursions below the audible frequencyrange. It operates essentially as a band-pass filter. Thelow frequencies are rolled off at 18 dB/octave with a–3 dB corner of 35 Hz (Butterworth response). Ultra-sonics are rolled off with a second order Bessel responseand –3 dB corner of 50 kHz.

A compression circuit in each channel may be switchedoff, on slow, or on fast by switches on the rear panel.This compressor is activated by either input overloador distortion (clipping). Input overload compression isin fast speed when the compressor switch is in the offposition. The compression ratio is infinite (it operatesas a peak limiter).

The four-quadrant topology used in the grounded out-put stages is called the Grounded Bridge, and it makesfull use of the power supplies. This patented topologyalso makes peak-to-peak voltages available to the loadwhich are twice the voltage any output device is everexposed to. The Grounded Bridge is covered in detailin Section 4.2.

The two channels may be used together to double thevoltage (bridged-mono) or the current (parallel-mono)presented to the load. This feature gives the user flex-ibility in maximizing the power available to the load.

Macro-Tech amplifiers utilize a wide bandwidth multiloopfeedback design with state of the art compensation tech-niques. This produces ideal behavior and results in ul-tra-low distortion values.

Aluminum extrusions have been widely used forheatsinks in power amplifiers due to their low cost andreasonable performance. However, measured on awatts per pound or watts per volume basis, that extru-sion technology doesn’t perform nearly as well as thecut fin radiator technology developed for the Macro-Tech 5002VZ power amplifier.

Our thermal diffusers are custom cut radiator fins on asolid heat sink block. They provide an extremely highratio of area to volume, or area to weight. All power de-vices are mounted directly to massive heat spreaders,which are electrically hot. Making the heat spreaderselectrically hot allows improved thermal performanceby eliminating the insulating interface underneath thepower devices. The chassis itself is used as part of thethermal circuit, and this maximizes utilization of the avail-able resources.

4.2 Grounded Bridge TheoryThe Grounded Bridge topology is ground-referenced


4-2 Circuit Theory

130446-1 Rev. A


Figure 4.1 Simplified Grounded Bridge

by the output stages rather than the power supply.Composite devices are constructed to function as gi-gantic NPN and PNP devices since the available cur-rents exceed the limits of existing individual devices.

The devices connected to the load are referred to as“high-side NPN and PNP” and the devices connectedto ground are referred to as “low-side NPN and PNP.”Positive voltage is delivered to the load by increasingconductance simultaneously in the high-side NPN andlow-side PNP stage. At the same time, conductance ofthe high-side PNP and low-side NPN is being de-creased.

4.2.1 Grounded Bridge OperationFigure 4.1 is a simplified example of Crown’s patentedGrounded Bridge output topology (ignoring the articu-lating characteristics of the VZ supply). It consists offour quadrants of three-deep Darlington (composite)emitter-follower stages per channel: one NPN and onePNP on the high side of the bridge (driving the load),and one NPN and one PNP on the low side of the bridge(controlling the ground reference for the rails). The out-put stages are biased to operate class AB+B for ultralow distortion in the signal cross-over region.

The high side of the bridge operates similar to a con-ventional bipolar push-pull output configuration. As theinput drive voltage becomes more positive, the high sideNPN conducts current and delivers positive voltage tothe speaker load. Eventually, full +Vcc is across the load.At this time the high side PNP is biased off. When thedrive signal is negative going, the high side PNP con-

ducts to deliver –Vcc to the load and the high side NPNstage is off.

The low side operates quite differently. The power sup-ply bridge rectifier is not ground referenced. This al-lows the power supply to deliver +Vcc and –Vcc fromthe same bridge rectifier and filter as a total differencein potential, regardless of their voltages with respect toground. The low side of bridge uses inverted feedbackfrom the high side output to control the ground refer-ence for the rails.

As the output swings positive, the output signal is fedback to the low side and is inverted to drive the lowside with a negative signal. The negative signal causesthe low side PNP to conduct (as the high side NPN con-ducts) shifting the ground reference toward –Vcc until,at the peak, –Vcc = 0V. At this time +Vcc equals the fullpotential (from rail to rail, not rail to ground) of the powersupply with positive polarity. Since the high side is de-livering +Vcc to the speaker load (which is ground ref-erenced at all times), the speaker sees the full potentialdeveloped by the power supply with a positive polarity.

When the input drive signal is negative and the highside PNP conducts to deliver a negative voltage to theload, that output is again fed to the low side and in-verted to cause the low side NPN to conduct. As thelow side NPN conducts, +Vcc swings toward the 0Vground potential. At the peak: +Vcc = 0V. At this time–Vcc equals the full potential developed by the powersupply, but with negative polarity. Since the high side isdelivering –Vcc to the speaker load, the load sees the

Circuit Theory 4-3



full (negative) potential developed by the power sup-ply.

The total effect is to deliver a peak to peak voltage tothe speaker load which is twice the (static) voltage pro-duced by the power supply. Benefits include full utiliza-tion of the power supply (it conducts current during bothhalves of the output signal; conventional designs re-quire two power supplies per channel, one positive andone negative), and never exposing any output deviceto more than half of the peak to peak output voltage(which does occur in conventional designs).

4.2.2 Output Stage CircuitryCircuitry on the positive and negative output modulesinclude bias circuitry, current limit circuitry, last voltageamplifiers (LVAs), pre-drivers, drivers, output devices,and the Low Side error amp. Temperature sensors arealso mounted to the heatsinks via the output modules.

The positive LVAs (Q501, Q502, and Q503) convert thenegative output of the voltage translator stage to a posi-tive drive voltage for the NPN High Side (HS) predriver.There are three LVA transistors in parallel due to thevery high voltages (therefore higher current and ther-mal requirements) that are present when the powersupply is in high voltage mode. D522 prevents the +LVAsfrom producing a high negative output to the HS NPNstage.

Q507, Q508, and Q509 are the -LVAs and are arrangedin mirror image to the +LVAs, including D513.

On the positive side, D514, D515, and C506 via the+LVAs act to limit slew rate. D514 and D515 also pre-vent dangerously excessive current through the LVAs.D516, D517, and C507 are the negative HS mirror im-age.

Q534 and Q540 provide two-speed current limiting inthe output stage. Sense lines are arranged such thatexcessive current through any single HS output devicewill result in current limit protection. Q535 and Q541 arethe negative side mirror image.

Q505 on the positive output module works in tandemwith Q505 on the negative output module as a Vbemultiplier circuit. They produce and, with great stability,control bias for the High Side NPN and PNP devices.Potentiometer R505 is used to precisely set bias volt-age. Bias voltage is easily measured from pin 2 (hot) topin 4 of ATE ports TP1 and TP2. Refer to Section 2 forappropriate test procedures.

Q504 is the HS NPN pre-driver and Q511 is the HSNPN driver. These devices are biased class AB for ul-tra low distortion in the zero-crossing region.

Q513, Q515, Q517, and Q536 are the HS NPN outputdevices. These devices are biased class B, in soft cut-off. Together with driver and pre-driver, they function asa three-deep Darlington. The output devices work inparallel as a giant composite. The over-all bias topol-ogy is referred to as AB+B, originally conceived andpatented by Crown engineers in 1966. This is still themost efficient, stable, and distortion free method usedtoday in BJT output stages.

D506 is the flyback diode for the HS NPN output quad-rant. In the event that a back EMF (flyback) pulse ex-ceeds power supply voltage, the flyback diode will shuntthis voltage to the supply in order to protect the outputdevices.

PNP pre-drivers, drivers, output devices, and flybackdiode D508 are a mirror image of the NPN side.

Overall, the High Side of the bridge operates much likea conventional output stage, but the Low Side (LS) isquite unique.

The LS senses output voltage and common buss (0.04ohms above ground) potential. The audio output is in-verted by U503. Also in the U503 input circuitry are staticand dynamic balance controls. These controls providea fine balance of the grounded bridge. Output of theop-amp drives the LS pre-driver circuits through the LSbias network.

LS bias is controlled in a fashion similar to that of theHS. Two transistors, Q529 and Q530, fix LS bias volt-age as measured from pin 15 (hot) to pin 13 of appli-cable ATE port TP1 or TP2. Potentiometer R556 adjustsbias in the LS.

Diodes D504 and D505 control polarity of applied LSdrive signal. Via the bias transistors, signal is deliveredto the bases of the pre-drivers Q527 (NPN) and Q528(PNP). Pre-drivers, drivers, and output devices in theLS operate class AB+B, exactly like the HS. The majordifference is that rather than driving a load, the NPNand PNP stages control the ground reference for thehigh voltage rails. As the HS NPNs conduct, LS PNPsconduct, and vice versa (as explained in section 4.2.1).

When the ODEP circuit senses that limiting drive is nec-essary to prevent a dangerous thermal condition, it pro-vides an output which limits drive to the output stages.For the HS, this limiting is accomplished on the mainmodule and is explained in section 4.4. For the LS, ODEPprovides (via wires labeled ±LL) a signal which limitsbias feed to the LS output devices. This is accomplishedthrough current mirrors Q532 and Q531 (LS NPN quad-rant), and Q542 and Q543 (LS PNP quadrant).


4-4 Circuit Theory

130446-1 Rev. A


4.3 VZ Power SupplyVZ means Variable Impedance and is the name ofCrown’s patented articulated power supply technology.It enables Crown to pack tremendous power into just5.25 inches of vertical rack space.

A power supply must be large enough to handle themaximum voltage and current necessary for the ampli-fier to drive its maximum rated power into a specifiedload. In the process of fulfilling this requirement, con-ventional power supply designs produce lots of heat,are heavy, and take up precious real estate. And it’s nosecret that heat is one of a power amplifiers worst en-emies.

According to Ohm’s Law, the bigger the power supply,the more heat the power transistors must dissipate. Also,the lower the resistance of the power transistors, themore voltage you can deliver to the load. But at thesame time that you lower the resistance of the transis-tors, you increase the current passing through them,and again increase the amount of heat they must dissi-pate.

4.3.1 VZ Supply OperationAn articulated power supply, like VZ, can circumventmuch of this problem by reducing the voltage appliedto the transistors when less voltage is required. Reduc-ing the voltage reduces the heat. Since the amplifierruns cooler, you can safely pack more power into thechassis.

The VZ supply is divided into segments to better matchthe voltage and current requirements of the power tran-sistors. Remember that audio signals like music arecomplex waveforms. Refer to Figures 4.2 and 4.3.

For music the average level is always much less thanthe peak level. This means a power supply does notneed to produce full voltage all the time.

The VZ supply is divided into two parts. When the volt-age requirements are not high, it operates in a parallelmode to produce less voltage and more current.

The power transistors stay cooler and are not forced toneedlessly dissipate heat. This is the normal operatingmode of the VZ power supply.

When the voltage requirements are high, VZ switchesto a series mode to produce higher voltage and lesscurrent. The amplified output signal never misses a beatand gets full voltage only when it needs it.

Sensing circuitry watches the voltage of the output sig-nal to determine when to switch VZ modes. The switch-ing circuitry is designed to prevent audible switchingdistortion to yield the highest dynamic transfer function— you hear only the music and not the amplifier. Youget not only the maximum power with the maximumsafety, you also get the best power matching to yourload.

In Figure 4.2, the individual components areshown. Upstream of the toroid transformer,though not shown, is where shutdown protec-tion and soft-start circuitry taps in to control ACmains input to the power supply. The VZ Controlcircuitry senses audio level and switches the ar-ticulating VZ supplies to either parallel (high cur-rent) mode for lower level audio, or series (highvoltage) mode for high program peaks.

Figure 4.3 shows current flow with power supplyand grounded bridge operating to-gether. Notice that the ungroundedVZ supply operates much like abattery. More exactly, it is a float-ing DC supply made up of two in-ternal batteries which operate ineither series or parallel.

In both examples it can be seen that when theMOSFET switch is off, the dual supplies areforced to operate in a parallel mode. Audio levelis sensed via a line tapping off the NFb loop.When audio level is rising and at about 80% ofthe parallel mode supply voltage, the MOSFETs(the switch is actually a three-device compos-

+VCC Buss

-VCC Buss

HI IHI VVZ ControlCircuitry(MOSFETs)

+

+–

–

Bridge 1

Bridge 2

D 810

D 811

Toroid

Figure 4.2 Simplified VZ Supply

Circuit Theory 4-5



Figure 4.3 Simplified VZ Supply in Operation

+

–

+Vcc (Positive Rail)

-Vcc (Negative Rail)

Load(speaker)

Inputsignal

HIGH SIDE LOW SIDE

Inverting Op-amp

R

V1

S1

R

V2

(+Vcc)

(-Vcc)

Parallel =Series =R = Switch Resistance

+

––

+

VZ Power Supply Grounded Bridge Output Topology&

ite switch) are turned on. No current will flow througheither of the control diodes (D810 and D811, as shownfor channel 1) because reverse polarity is appliedthrough the MOSFET switch. Since this happens to bothrectifier sources at the same time, and the negative sideof Bridge 1 is then shorted to the positive side of Bridge2, the supplies are forced to operate in series mode.Like two batteries, the supplies will provide double volt-age in series mode, double current in parallel mode.

Although shipped from the factory in VZ-ODEP mode,the user may switch modes to Lock Low voltage (highcurrent), or operate the supply in VZ-AUTO mode. VZ-ODEP is similar to VZ-AUTO mode, except that in AUTOmode, in the event ODEP is activated to protect theamplifier, the VZ will automatically lock into low voltage(high current) mode. While this mode of operation willcool the amplifier more quickly in the event that the ther-mal reserve is exhausted, it may cause voltage clip-ping rather than ODEP limiting. Seldom will the ampli-fier be operated locked in high current mode unless avery low impedance is being driven.

4.3.2 VZ Supply CircuitryFor simplicity, only channel 1 circuitry will be coveredunless noted otherwise. The actual VZ switch circuit islocated on the VZ switch assembly. This assembly con-tains the filter capacitors, MOSFET switches, and con-trol diodes (D810 and D811). Three MOSFETs are usedin parallel for sharing the high current supplied to therails. Operation of this section was covered in detail,minus circuit designations, in Section 4.3.1.

WARNING: From a service standpoint, it is criticalto note that VZ switch control circuitry is NOT groundreferenced. Any attempt to take voltage measure-ments using a ground reference when voltage isapplied will not only be unreliable, but may be ex-tremely dangerous. Serious damage to equipmentor personnel may occur if this is attempted.

The output of a 555 timer (U703) on the control moduledetermines whether the MOSFETs are switched on(high) or off (low). This 555 device and the varioussources that feed the 555 are the things that make thearticulation work.

The master 555 trigger is controlled by the output of


4-6 Circuit Theory

130446-1 Rev. A


U702A. S700, physically accessible from behind thefront grille, determines the VZ operating mode. In highvoltage mode (Q42930-0 Control Module only) the out-put of U702A is held low. This in turn keeps the 555output high and the MOSFETs are kept on. In the highcurrent mode, U702A is held in the opposite polarity,keeping the output of the 555 low and the MOSFETs off.In the AUTO position of S700, the audio level sensecircuitry controls the threshold and reset inputs to the555. The 555 will then switch states to high voltage whenthe audio level is sufficient and will switch back downautomatically when level has dropped sufficiently. Ca-pacitors in the U705 circuitry control the speed of thedown-shift. In the VZ-ODEP mode, the switch operatesas it would in AUTO mode unless ODEP limiting is inprogress. When ODEP limiting occurs, optic couplerU704 pulls the reset control low to the 555 to turn theMOSFET switches off, and keep them off (low voltage/high current mode) until the ODEP limiting conditionclears.

Upstream of the toroids are the soft-start and protec-tion mechanisms used to power down the amplifier.Although tied into the power supply primary, these cir-cuits are covered in Section 4.6, Protection Systems.

The low voltage power supply utilizes a separate trans-former. The front panel power switch and a 1A fuse(F702) are the only components upstream of this trans-former. The output of the rectifier produces ±24VDCunregulated. U715 and U716 produce regulated±15VDC respectively. (A separate fullwave rectifier pro-duces pulsed DC for Over-voltage sense and Soft-startcontrol.)

4.4 ODEP TheoryTo protect the output stages from adverse thermal con-ditions, a specially developed “ODEP” (Output DeviceEmulator Protection) circuit is used. It produces a com-plex analog output signal proportional to the alwayschanging safe-operating-area (SOA) margin of the out-put transistors. This output signal controls the VoltageTranslator stage and Low Side output stage bias. Thisaction removes only the drive that may exceed the safe-operating-area of the output stage.

Thermal sensors give the ODEP circuitry vital informa-tion on the operating temperature of the heat sinks onwhich the output devices are mounted. This tempera-ture signal combines with the complex ODEP signal toform the heart of our patented ODEP protection scheme.

4.4.1 ODEP OperationRefer to Figure 4.4 for a diagram of the basic operationof the ODEP system.

The ODEP circuitry actually comes in two parts, onepositive and the other negative. For the purposes ofthis discussion, only the channel 1 ODEP circuitry iscovered here, and the focus will primarily be on thepositive half.

An LM-334Z thermal sensor provides a calibrated out-put from the output modules. At 25°C its output is 2.98V,with a 10 mV increase per every 1°C rise in heatsinktemperature.

This thermal sensor output, from the positive sensor,goes to three destinations. First is a buffer which drivesthe calibrated temperature test point at pin 7 of TP1/TP2. Second is an over-temperature limit trip (thermallimit amplifier, as shown below). This will cause boththe positive and the negative ODEP circuit to go into,and remain in, hard ODEP until the heatsinks cool. Third,it goes down into a circuit which combines thermal andoutput power information.

The thermal sensor from the negative output moduleonly performs this last function.

A pair of sense lines from the Low Side emitter resistorsprovide current information. Combined with VCC infor-mation, actual instantaneous power is calculated. Acombining circuit determines the net thermal conditionbased on the power being delivered for the existingheat level. The ODEP amplifier accepts this input infor-mation and, using an RC model of the heat transfercharacteristics of the output devices (as mounted inthe heatsinks), creates a complex output proportionalto the thermal reserve of the output devices.

Output from the positive ODEP amplifier ranges from– 12V (cold) to +9V (hard ODEP). This output drives thepositive LS bias feed control circuit (see Section 4.2.2)and the negative HS Voltage Translator feed control cir-cuit (see Section 4.5.2). Also, this circuit provides testpoint monitoring information and VZ-ODEP VZ modecontrol information.

Output from the negative ODEP amplifier ranges from+12V (cold) to – 9V (hard ODEP). This output drives thenegative LS bias feed control circuit (see Section 4.2.2)and the positive HS Voltage Translator feed control cir-cuit (see Section 4.5.2). Also, this circuit provides testpoint monitoring information, VZ-ODEP control informa-tion, and front panel ODEP (thermal reserve) LED con-trol information.

Also tapping into the ODEP output control of LS biasfeed and Voltage Translator feed are signals from thefault, power (turn-on delay), and power loss (brown-out) circuits. By using the output of ODEP for ±LL and±LH control, these sources can mute the audio to the

Circuit Theory 4-7



ODEP Inputs:Temperature±VCCOutput Current

ODEP Outputs:Calibrated Temperature, for monitoring±ODEP Level, for monitoring±ODEP Level, for Bi-ODEP control of VZ Supply±ODEP Level, to limit drive at ±Voltage Translators (±LH)±ODEP Level, to limit Low Side Bias (±LL)ODEP Indication (front panel LEDs)

+Temp 1

Channel 1 ODEP Circuitry shown

+IC 1

+ICOM 1

Common Output Buss

Q519 LSOutput

Re

+VCC+VCC

RC NetworkThermal Model

+ODEP Output

+ODEP Amplifier

Calibrated Temperature Output

LM-334ZThermal Sensor(+2.98V at 25˚C,+10mV/˚C Rise)

Buffer Amplifier

Thermal Limit Amplifier

-IC 1

-ICOM 1

Q524 LSOutput

Re

-VCC-VCC

RC NetworkThermal Model

-ODEP Output

-ODEP Amplifier

-Temp 1

LM-334ZThermal Sensor

PWR LOSSPWR 1FAULT 1

+LL 1

-LH 1

-LL 1

+LH 1

On Main ModuleOff MainModule

-12V

+9V

Cold

Hot

+12V

-9VCold Hot

output stage: a. until power-up delay has timed out; b.immediately upon indication of any failure mode; c. im-mediately upon loss of AC mains (power-down or ac-tual loss of AC service).

4.4.2 ODEP Circuitry±TEMP signals are produced by U500 and U501 onthe output modules. U108, on the main module, is abuffer which drives the temperature sense test point.U117A has a fixed window voltage of 6.2V via ZenerD129. If heatsink temperature level exceeds about130°C, U117A output will cause both the positive andnegative ODEP amplifiers to go into hard ODEP limit-

ing. When the thermal condition clears, this limiting con-dition will also clear.

+VCC enters via dual PNP transistor pack U116.Positive ODEP bias is adjusted by R182. The voltage atthat point controls the static balance of the U116 de-vice. U116 combines the VCC and output current senseinformation, the output of which represents output powerlevel. The common output is brought into RN101 whereit provides the reference for temperature and power.U112B is the active device and, together with the powersignal, drives the ODEP amplifier U112A. The RC net-work in the feedback path of U112A models the ther-mal junctions from output device die to housing, hous-

Figure 4.4 Simplified ODEP Circuitry


4-8 Circuit Theory

130446-1 Rev. A


ing to case, and case to heatsink under both static anddynamic conditions.

The output of the positive ODEP amplifier drives +ODEPtest point pin 11. It also drives U114A and U114B whichin turn drive – LH and +LL respectively. The output ofthe negative ODEP amplifier drives the ODEP indica-tion circuitry and – ODEP test point pin 9. Negative ODEPalso drives U114C and U114D which in turn drive +LHand – LL respectively.

Also entering the U114 comparator networks are thePWR (power relay engage), PWRLOSS (brown-out), andFAULT (any protection which shuts down the amplifier)signals via blocking diodes. If any of these signals droplow, the feed to the LS bias and Voltage Translator drivewill be shut down via ±LL and ±LH. This action mutesall audio in the event of a dramatic failure.

4.5 Front End TheoryFigure 4.5 explodes the front-end portion of the overallblock diagram. Once again, only channel 1 will be dis-cussed in detail.

Input to the amplifier is only via a PIP module. The stan-dard module shipped with the MA-5002VZ is the PIP2-FXQ. Whether this, or any other module is used, theamplifier senses a balanced input from the installedmodule.

4.5.1 Balanced Gain StageThe Balanced Gain Stage (BGS) amplifier U100A con-verts the input audio from a balanced configuration tosingle-ended with (electrical) unity gain. The compres-sion device is essentially a resistive shunt across thebalanced BGS input. The BGS drives the Variable GainStage and provides information to the compressor con-trol circuit and to the PIP connector.

4.5.2 Variable Gain StageThe Variable Gain Stage (U100B) taps signal from thewiper of the front panel level control (R120). Gain of thefront-end is set by the gain of this stage. The sensitivityswitch (S100, located on the rear panel) selects theamount of gain in this stage. Overall amplifier sensitivitymay be set for 26 dB fixed gain (about 5.1Vrms), 1.4V,or 0.775V. Since overall amplifier gain after this stage is26 dB, this stage will have a fixed gain of 0 dB (26 dBsetting), about +12 dB (1.4V setting), or about +16 dB(0.775V setting). The output of this stage drives the Er-ror Amp.

4.5.3 Error AmpThe Error Amp (U105) input comes from the VariableGain Stage with or without Loudspeaker Offset Integra-tion (LOI), and is summed with amplifier output in a nega-tive feedback (NFb) configuration. Output of the ErrorAmp drives the Voltage Translators and provides error

Figure 4.5 Front End Circuitry Block Diagram

Circuit Theory 4-9



signal information. An error signal (spike) is producedany time the shape of the output waveform differs fromthe output of the Variable Gain Stage and LOI by morethan 0.05%. This error signal drives the error signal (ES)input to the PIP connector, the error signal sense testpoint, and the compression control circuit.

4.5.4 CompressorThe compression circuitry senses error signal and BGSlevel. If the BGS overloads, or an error signal is present,the compression control circuit (U101) produces a com-pression drive pulse. A switch on the rear panel selectsthe speed of the integrator circuit to follow. In the offposition, the error driven compression is disabled, butthe input overload compression remains on (in fastspeed) to protect the front end. The compression drivepulse also drives the IOC Integrator (U102). The IOCintegrator not only tells the IOC indicator circuit when toturn on, but ensures that the indicator will remain onlong enough to be visible to the human eye.

The compression integrator (U102, Q100) sets com-pression speed and produces an output pulse whichcontrols attack and decay times. An optic device (U103)provides a resistive shunt to the input audio accordingto the degree of compression required and the dura-tion of that compression. The amplifier input impedanceis not affected by compressor operation.

4.5.5 Loudspeaker Offset IntegrationLOI (U104A/B) senses amplifier feedback and preventsdynamic DC offset. It operates essentially as a dual fil-ter system with band pass from about 35 Hz to about50 kHz. The upper roll-off has a second order Besselresponse while the lower roll-off has a third orderButterworth response.

4.5.6 Voltage Translator and LVA StagesThe Voltage Translator stages (Q104, Q104) channelthe signal to the Last Voltage Amplifiers (LVAs, locatedon the output modules), depending on the signal polar-ity, from the error amp U105. The ±LVAs, with their push-pull effect through the High Side bias servo devices,drive the fully complementary output stage. For moreinformation on the LVAs, refer to Section 4.2.

U106 and U107 bring in feedback information and pro-tection muting to the Voltage Translator stages. The feed-back controls gain from the Voltage Translators to theoutput jacks. The protection inputs (±LH) pull off feedto the Voltage Translators in proportion to ODEP limit-ing, and completely shut down the feed in the event ofpower-down or a Fault.

4.5.7 Inverting StagesOverall, the amplifier is non-inverting. Four stages withinthe amplifier, however, do invert the audio signal for anet non-inversion. The individual stages are: the BGS,which inverts the audio; the Variable Gain Stage, whichinverts it back; the input side of U106 and U107 (whichdrives the Voltage Translators) re-inverts the audio (theVoltage Translators are a common-base configurationfor high voltage gain); and finally, the LVAs invert theaudio for the last time for a net non-inversion throughthe amplifier.

4.6 Protection SystemsThe MA-5002VZ has several protection mechanisms tolimit drive or shutdown the amplifier completely in theevent of a fault of almost any kind. Mechanisms include:ODEP (covered in depth in Section 4.4), current limit(covered in Section 4.2.2), over-voltage (on AC mains),DC/LFI, common mode output current, output thermal,transformer thermal, FET thermal, loss of AC mains,compression (covered in Section 4.5.4), LOI (coveredin Section 4.5.5), and slew rate limit (covered in Section4.2.2). After any non-latching fault which has shut downthe amplifier clears, the amplifier will automatically powerback up via soft-start. Because the fans within the MA-5002VZ cool the amplifier (under normal conditions) toprevent thermal shutdowns and ODEP limiting, the fancontrol circuit is also covered in this section.

Refer to Figures 4.6, 4.7, and 4.8. Figure 4.6 shows soft-start and fan control. Figure 4.7 shows the soft-start con-trol signals. Figure 4.8 shows the over-all protectionscheme of the MA-5002VZ. Each augments the others,and explode the basic block diagram of the unit (Fig-ure 4.9).

4.6.1 Soft-startSoft-start circuitry controls the rate at which power isinitially applied to the primary of the toroid transformersfor the high-voltage power supplies. For ease of expla-nation, assume the amplifier is operating properly andis just being turned on from the front panel power switch.

Before the power switch push-button is depressed, theinput to the low voltage supply is open. The high volt-age supply is isolated via input relay K700 and triacQ701 (which is in parallel with K700).

Several things occur immediately at turn-on. First, thelow voltage supply powers up and produces its mainunregulated ±24VDC and regulated ±15VDC. It alsoimmediately produces pulsed DC via full-wave rectifierD709/D714.


4-10 Circuit Theory

130446-1 Rev. A


As this occurs, all op-amps in the amplifier receivepower, including front-end stages, relay power controlU111C, and standby control U111B. The output ofU111C powers relay K700 via relay drive transistorQ700. When the output of this op-amp goes high, Q700turns on and the relay closes. The output of U111C isheld low until the amplifier delay times out by compar-ing a high voltage on its inverting input to an RC net-work voltage on its non-inverting input. R329 and R330fix a window at about +10.4VDC. At turn-on, C220 (a10 µF cap) is fully discharged. In that first instant, it keeps– 15V on the non-inverting input of U111C, keeping itsoutput low. As the capacitor charges it produces aramped rise in voltage as it charges through R327. Af-ter about 4 seconds, the voltage between R327 andR328 exceeds the window voltage and U111C outputgoes high, in turn causing relay K700 to close.

Note: Any protection signal within the amplifier which isused to shut it down will discharge this capacitor (C120),immediately causing the relay (K700) to open. Uponclearance of such a shut-down protection signal, thecharge will begin again with the same ramp effect andsame delay.

The ramped voltage on the capacitor C120 is alsosensed by Standby amplifier U111B. Its unity gain out-put is non-inverting. It drives the Soft-start op-amp(U701A) inverting input with its ramp to control the rateat which the field develops in the toroid. On the non-inverting input to U701A is the pulsed DC drive fromthe U701B/Q708 pulse circuit. Jumper JP1 may be setto 50 or 60 Hz, but must be set properly to have thecorrect pulse width for soft-start. Pulse width is deter-mined by C717 and either R777 (50 Hz) or R777 in par-allel with R806 (60 Hz).

STANDBYDRIVER

VOLTAGEDIVIDER

WITH C120

+15V

-15V

-+

+10.4V

LOWVOLTAGEPOWERSUPPLY

+15V-15V+24V-24V

DC PULSEWIDTH

CONTROL

POWERON

RELAYDRIVE

RELAYK700

SOFT-STARTDRIVER

-+

POSITOR5.0 OHM

FANDRIVERS

-+

TEMPERATURE CH 1

TEMPERATURE CH 2

ODEP CH 1

ODEP CH 2

CH 1 FANCONTROL

CH 2 FANCONTROL

POWERSWITCH

TO CH 2 SOFT-START DRIVER

Portion ofMain Module

POWERXFMR

FANS

FAULTDC/LFI

OV/TSWPWRLOSS

TSW1

TSW2

Figure 4.6 Soft-start and Fan Control

Circuit Theory 4-11



The output of U701A controls the Soft-start. Refer toFigure 4.6 for a graphic of Soft-start operation.

When the output of U701A goes low, the opto-triac de-vice U700 turns on. While on, the input triac Q700 con-ducts. Positor R702 limits peak input current to the tor-oid to a maximum of 22A peak (with 120VAC mains).U701A combines the sloped input from the C120 cir-cuitry on the main module with the pulsed DC. As theportion of time which the output of U701A goes low in-creases, the amount of time where AC mains conductto the transformer (via Q700 and R702) increases untilit remains on. When the U111C PWR circuit times out,the relay closes, bypassing the current limiting soft-startcircuit. Soft-start control signals are shown in Figure 4.7.The upper signal is that produced by C120. At time 0the amplifier is off. At time 1 the power switch is pressed(on). At time 2 C120 has fully charged, the magnetic

fields have built up in the high voltage supply, and themain relay closes. At time 3 a protective action occurs;note that the DC supply remains. At time 4 the condi-tion clears and the restart begins. Time 5 is akin to time2, and time 6 is another protective action. The lowergraph shows Q701 operation (high = on).

Any time a protection mechanism has acted and thecondition then clears, this entire process repeats.

4.6.2 Over-voltageOne mode of amplifier protection is a shutdown in theevent of over-voltage on the AC mains. This is sensedby the pulsed DC signal produced by the full-wave rec-tifier in the low voltage supply.

R780 picks off the pulsed DC, and U707D will, if thevoltage is too high, shift its output to a low. When thishappens, the over-volt/therm red LED on the control

module lights and signal OV1 goes lowto the main module.

A low (over-voltage condition) onOV1 causes U211C to shift to alow output. This low, through D1,causes C120 to discharge im-mediately. This in turn causes themain relay to drop out, soft-startto reset, and the ±LL and ±LHto clamp audio drive. Over-volt-age is a non-latching fault con-dition.

4.6.3 DC/LFThe amplifier senses its own out-put for DC or very low frequencyand will interrupt the amplifierchannel in the event of DC or lowfrequency.

The feedback loop is sensed forvoltage and the current sensesignal provides current informa-tion. An RC network at the inputto U109C/D will prevent the LFcircuit from activating with nor-mal audio frequency material,and will ensure activation withhigh level subsonic currents orvoltages.

If U109C/D sense a DC (or LF)level, it will output a low, whichwill, through D102, dischargeC120 and initiate power supply

0 1 2 3 4 5 6

0 1 2 3 4 5 6

0 1 2 3 4 5 6

C120CHARGEVOLTAGE

PULSEDDC FROM

LVPS

SOFT-STARTTRIAC

CONTROL

Figure 4.7 Soft-start Signal


4-12 Circuit Theory

130446-1 Rev. A


shutdown. A low will also cause the DC/LF red LED onthe main module to light. DC/LF is a non-latching pro-tection mechanism.

4.6.4 Common Mode Output CurrentCommon mode current in the output stagecan only be due to an output stage failureor full power output of RF energy. Com-mon mode current occurs when a highcurrent level exists in both the positive andthe negative halves of the output stage.

U115 is a specialty device. It serves asboth an Opto-SCR, and as a conventionalSCR. It must have both an optic gate andconventional gate firing at the same timein order to latch. The conventional gate isfired by current sense of the output stageLow-side. The optic gate is fired by theHigh-side current sense. If high currentsexist in both sides simultaneously, the SCRwill latch on, and remain on until the unit isturned off.

When the SCR latches, low voltage causesthe red LED (labeled Output Module) tolight, and places a low on the FAULT sig-nal line. A low on the FAULT line is sensed,via D112, by C120. Once again, a low heredischarges C120 and shuts down the am-plifier. FAULT is a latching protectionmechanism (the only one in the amplifier).

4.6.5 Output ThermalOutput over-temperature protection hasbeen covered, to a degree, in Section4.4.2, ODEP Circuitry. The calibrated tem-perature sense from the positive half of theoutput stage drives an over-temperatureamp, U117A. If heatsink temperature ex-ceeds a limit of about 130°C, the amplifierwill go into hard ODEP. This does not shutdown the amplifier, but does clamp the au-dio. Refer to Section 4.4.2.

4.6.6 Transformer ThermalThe main power transformers have built-in thermalswitches which open in the event of transformer over-temperature. In the event that the thermal switch opensin the channel 1 toroid, Q709 turns on, causing U707Dto go low. When it does, the over-voltage/thermal switchLED on the control module is energized and the OV1signal is tripped; the fans are also forced to high speed.Transformer thermal protection is self-resetting. This

results in amplifier shutdown by way of shared over-voltage circuitry. Refer to Section 4.6.2.

4.6.7 FET ThermalA special circuit has been designed into the MA-5002VZto protect the MOSFET switches in the VZ supply. Thevoltage drop across the FETs (while conducting) is pro-portional to device temperature. Control circuitry sensesthe voltage and, if necessary, the supply will be forcedinto low voltage (high current) mode to allow the FETdevices to cool.

DC PULSEWIDTH

CONTROL

-+

+10.4V

MAINRELAY

-+ SOFT-

START

OVER-VOLTAGE

-+

TOROIDTHERMALSWITCH

±15VDCSENSE

FAULTSENSE

LS NPN CURRENTHS NPN CURRENT

±LL & ±LHFOR LS BIAS &V XLTR FEED

CONTROL

DC VOLTAGE &CURRENT SENSE

To Ch 2To Ch 2

OV/TSW

OV/TSWRED

x1 BUFFER

PWR LOSS

OUTPUTMODULE

RED

FAULT

DC/LF

DC/LFRED

-15V

+15V

C120

PWR

STANDBY

SOFT-STARTCONTROL

0 1

V

REMOTESTANDBYFROM PIP

STBYRED

Figure 4.8 Over-all Protection Scheme

Circuit Theory 4-13



4.6.8 Power LossThe MA-5002VZ has the ability to sense a “brown-out”condition on the AC service. This is accomplished bysensing the low-voltage power supply at U111A. Localcapacitors on the ±15VDC keep this chip powered fora short time after the low voltage supply drops out onpower-down/loss.

An RC network, consisting of C1 and R6, will cause theoutput of U111A to shift low the instant low voltage islost. This negative potential discharges C120 causingimmediate opening of the main relay, and reset of theSoft-start circuitry. It is essential that C120 be dischargedimmediately in the event that power is restored beforeC120 would otherwise discharge. The power-loss cir-cuit is common to both channels. Its output goes to±LL and ±LH to immediately mute audio upon power-down or power-loss, thus preventing turn-off audio noise.

4.6.9 Fan ControlThe MA-5002VZ, unlike other members of the Macro-Tech family, has two onboard fans. They are mountedto the chassis divider assembly and pull cool air fromthe front and discharge it across the output stageheatsinks to the rear of the amplifier. Also unlike the otherMacro-Techs, the fans are fully ODEP proportional (theyoperate in proportion to output stage temperature andcalibrated ODEP control voltage).

U713B combines channel 1 temperature and ODEPlevel, U713A for channel 2. D706 and D707 form a di-ode OR gate. The output of the OR gate drives oneinput to U707B. The other input to U707B is from theDC pulse width control circuit (U701B). U707B oper-ates in a fashion similar to that of U707A, the Soft-startcontrol amplifier. A graphic example of the fan controlwaveforms would look a good deal like those in Figure4.7, except that the thermal drive would be unique fromthat of the Soft-start ramp.

The fans will also be forced to operate at full speed inthe event a toroid transformer thermal switch trips open.

4.7 DisplayAmplifier front panel indication includes a total of 7 LEDs.These include Enable, ODEP, SPI/IOC, and ILOAD/ILIMIT.

The Enable indicator is an amber light which indicatespresence of the low voltage supply. It is powered by theunregulated +24VDC supply. It will be on any time thepower switch is depressed (unless the low voltage fuseblows).

ODEP indicators provide an on-line indication of ampli-

fier thermal reserve. The LEDs are amber (although theymay have a reddish appearance) and are normally on.They dim and/or extinguish in the event that theamplifier’s thermal reserve is exhausted. ODEP indica-tors will also extinguish whenever the main supply re-lays are open (such as a protection action being acti-vated, or during Soft-start time-out).

Green SPI/IOC LEDs show signal presence (SPI) andany form of distortion (IOC). They flash dimly with theaudio to show signal. In the event of an IOC condition(output waveform differs from input by >0.05%, or inputoverload) the light will be on brightly. An occasional flashof IOC usually indicates clipping. If the IOC light locksin, it usually indicates a protective action, or “hard” ODEPlimiting.

ILOAD/ILIMIT LEDs flash green with the audio when pro-gram material is being delivered to a load. Its functionis similar to that of the SPI, except that SPI is voltagedriven and does not require a load. ILOAD comes onwhen the amplifier is loaded, and its brightness is inproportion to the output current. This is the ILOAD func-tion. In the event of current limiting action, the light willflash to red. This is the ILIMIT function.

4.8 Mono ModesThe MA-5002VZ has three main operating modes,namely dual (stereo), bridge mono, and parallel mono.

There are a number of precautions which should betaken when operating the amplifier in either of the monomodes. The VZ mode switches for each channel mustbe set to the same setting. Sensitivity, LOI, and Com-pressor switches for channel 2 make no difference. Theinput must be to channel 1 only. The input to channel 2and controls for channel 2 are NOT defeated in eithermono mode, therefore no connection to channel 2 maybe made in either of the mono modes. The channel 2level control should be turned down (counterclockwise)fully in either mono mode.

Monaural amplifier operating modes are covered indetail in the MA-5002VZ Reference Manual. The dis-cussion below primarily aids in understanding how themono modes work for testing purposes.

4.8.1 Bridge MonoBridge mono is intended for loads of 4 ohms or greater.The feedback loop for channel 1 also drives the inputto channel 2 in this mono mode. The input to channel 2is, however, inverted. This causes the output of chan-nel 2 to be of equal magnitude and opposite polarity(for double voltage output). The output of the amplifier


4-14 Circuit Theory

130446-1 Rev. A


is balanced, and channel 1 hot output is connected toload hot (+), channel 2 hot output is connected to loadreturn (– ).

4.8.2 Parallel MonoParallel mono is intended for loads less than 4 ohms(as low as 1 ohm) in a monaural amplifier configuration.

The channel 1 and 2 amplifier hot outputs must beshorted by an external shorting buss (10 AWG or larger).The amplifier output to the load(s) is taken from eitherchannel’s hot output to load hot, and either channel’snegative output to the load return (– ). The shorting bussmust be removed prior to changing from parallel monoto either other mode.

Figure 4.9 Macro-Tech 5002VZ Amplifier Block Diagram

Maintenance 5-1



5.1 Cautions and WarningsDANGER: The outputs of this amplifier can produceLETHAL energy levels! Be very careful when makingconnections. Do not attempt to change output wiringuntil the amplifier has been off at least 10 seconds.WARNING: This unit is capable of producing high soundpressure levels. Continued exposure to high sound pres-sure levels can cause permanent hearing impairmentor loss. User caution is advised and ear protection isrecommended when using at high levels.WARNING: Do not expose this unit to rain or moisture.WARNING: Only properly trained and qualified techni-cians should attempt to service this unit. There are nouser serviceable parts inside.WARNING: When performing service checks with thepower off, discharge the main power supply filter ca-pacitors fully before taking any measurements or touch-ing any electrical components. A 300-ohm 10-W resis-tor is recommended for this. Hold the resistor with pli-ers, as the resistor may become extremely hot.WARNING: Under load, with a sine wave signal at fullpower into both channels, the amplifier may draw inexcess of 30 amperes from the AC service mains.WARNING: Do not change the position of the ModeSwitch when the amplifier is turned on. If the position ofthis switch is changed while the amplifier is powered,transients may damage your speakers.WARNING: Heatsinks are not at ground potential. Si-multaneously touching either heatsink and ground, orboth heatsinks will cause electrical shock.CAUTION: Eye protection should be worn at all timeswhen protective covers are removed and the amplifieris plugged in.CAUTION: Disconnect the power cord before install-ing or removing any cover or panel.

5.2 General InformationIn most cases you will be using the test procedures inSection 5.4 after conducting your repairs. Before ini-tially powering up the amplifier you should review Sec-tion 5.1 and take appropriate steps for personal andequipment safety. Section 5.3 will help to determinewhether the amplifier should be safe to turn on.Thissection also includes some additional checks thatshould be made prior to starting the actual check-out.Italicized print in the test procedures (Section 5.4) in-cludes basic troubleshooting hints to augment proce-dures in Section 5.3. These hints do not cover everypossibility, but should be helpful for a variety of symp-

toms. After troubleshooting and repair (or as a part of),the final step is to thoroughly test the amplifier to becertain that it meets the factory specifications. Test pro-cedures in Section 5.4 will help you do this as well asaid you in locating the cause of problem(s).

5.3 Troubleshooting5.3.1 Pre-AC-ChecksA number of checks can be made prior to powering upthe unit. These should be done in order to prevent anunwanted disaster when turning the unit on. Once thesechecks are made power may be applied for furtherchecks. Note: It will be necessary to remove top, rear,and bottom panels for complete access to all modules.

Step 1: Acquire all information possible from theperson(s) having the problem to determine the natureof the complaint. Ask questions like “Why was the am-plifier brought in for repair?” “Does it do this right at turnon, does it take a while, or does it only happen some-times?” If you observe nothing wrong, inquire tactfullyhow the unit was being used when the malfunction oc-curred to determine if it may have been misused, if theuser misunderstood what happened, or if another sys-tem component may be at fault.

Step 2: Always do a complete visual inspection. A prob-lem may be obvious just by looking. Things to look forinclude burned components, wires not connected, fanobstructions, loose hardware or connections, and sol-dering. Dirty air filters or plugged heatsinks greatly re-duce amplifier efficiency and result in pre-mature ODEPlimiting. The fan blades should spin freely. Burns andother physical damage should be repaired and com-ponents in the affected circuit areas should be checkedcarefully before continuing.

Whether a problem is identified by visual inspection ornot, several checks should be performed prior to turn-ing the amplifier on. These should be performed if cata-strophic failure has been reported, no signal output withconstant IOC is reported, or the condition of the ampli-fier is otherwise unknown but failure is suspected.

Channel 1 uses 100/300 series numbering and chan-nel 2 uses 200/400 series numbering on the main mod-ule. 500 series numbering is used on the output andemitter modules, regardless of the channel. 700 and800 series numbers are used on control, current sense,and terminator modules.

The third item on the “to do” list involves a number ofelectrical checks. Due to the protection features of theMA-5002VZ, it should be safe to turn-on under all cir-cumstances, but these preliminary checks may allow a

5 Maintenance


5-2 Maintenance

130446-1 Rev. A


partial, if not complete, repair before power is ever ap-plied. These checks are designed to find problems inthe output stages. The ultimate guide should always becommon sense.

To access all of the modules, simply remove the topcover, rear panel, and bottom cover. The main modulewill slide up and back for access to output module com-ponents by loosening four screws. The main moduletray need not be removed in order to remove an outputassembly, however, to perform component replacementon the main module the tray should be removed com-pletely and the module removed from the tray. Note thatthe current sense module is actually comprised of twoseparate boards, connected by dual ribbon cables,hardwired at both ends. The smaller board is calledcurrent sense, the larger is, by itself, referred to as theterminator. Either name, however, may be applied tothe pair. In Section 8 they are covered as a single part,D 7994-3.

a.) Locate the flyback diodes D506, D507,D508, and D509 on the emitter modules and check forindications of a short. If a short is indicated, this meansthat an output device or driver transistor in parallel withthat diode is shorted, usually not the diode itself. If afaulty output device is found, the entire output assem-bly may be replaced, or only the affected components.If an output device is found to be defective, emitter re-sistors should also be checked. If no output device isfound defective, perform a quick check of driver, pre-driver, and bias transistors. Then, if no problem is found,move to power-on checks.

b.) Check driver and pre-driver transistors forshorts or opens. If a fault is found, do an in-circuit staticcheck of all semiconductors on the output modules. Ifno output device and nothing upstream is found defec-tive, move to power-on checks. Otherwise continue.

c.) If a failure has occurred anywhere in theoutput stages, check bias servo transistors on each(positive and negative) output module. Any failure as-sociated with bias transistors may result in repeat fail-ure of the affected channel even if all other defectivecomponents have been found and replaced.

d.) If a failure is found in any LVAs, checksshould continue up onto the main module in the volt-age translator stage.

e.) Failure within the power supply itself is veryrare, however a cursory check of major items is alwaysprudent. A 30A fuse should not blow unless a cata-strophic failure has occurred in the output stage orpower supply. The low voltage fuse should not blowunless a failure has occurred, probably in the supplyitself. If a failure has occurred in the output stages, checkthe MOSFET switches and other VZ control components,such as bridge rectifiers.

5.3.2 LED ChecksWhen power-off checks are complete and any defectsfound are corrected during that phase, the next step isto apply power. The MA-5002VZ includes several LEDindicators to assist you in troubleshooting an amplifiermalfunction.

All indicators on the amplifier, both front panel and in-ternal, are important. External indicators include Enable,ODEP, SPI/IOC, and ILOAD/ILIMIT. Internal indicators in-clude DC/LF, Fault (output module), Standby, and Over-voltage/Transformer Thermal.

A chart on the following pages lists likely LED combina-tions and likely causes. In each case it is assumed thatthe LED circuit itself is operating properly. If a failure issuspected, compare amplifier indicators with the chart.

In order to ensure that the problems are assessed cor-rectly, perform the LED checks under the following con-ditions: Before power is applied, ensure that the Ste-reo/Mono switch is in the STEREO position. Do NOTconnect any signal source or load to the amplifier. Turnthe amplifier on. After approximately 4 seconds the turn-on delay should time out. During the delay, IOC indica-tors will usually be on and ODEP indicators should beoff. After the delay times out, relays click on, IOC indi-cation should go off, and ODEP indicators should comeon. If this does not occur, definitely refer to the chartthat follows. Although this chart contains most likely fail-ures, it does not cover every possibility. Common senseand a study of schematics and circuit theory (providedin Section 4) should ultimately lead to a proper repair.

Maintenance 5-3



Indicator ConditionODEP One OFFSPI/IOC Both OFFILOAD/ILIMIT Both OFFSTBY Both OFFOV/THERM Both OFFDC/LF Both OFFOUTPUT MOD Both OFF

ODEP One OFFSPI/IOC Both OFFILOAD/ILIMIT Both OFFSTBY One/Both ONOV/THERM Both OFFDC/LF Both OFFOUTPUT MOD Both OFF

ODEP Both OFFSPI/IOC Both OFFILOAD/ILIMIT Both OFFSTBY Both OFFOV/THERM Both ONDC/LF Both OFFOUTPUT MOD Both OFF

ODEP One OFFSPI/IOC Both OFFILOAD/ILIMIT Both OFFSTBY Both OFFOV/THERM One ONDC/LF Both OFFOUTPUT MOD Both OFF

ODEP One OFFSPI/IOC One ONILOAD/ILIMIT Both OFFSTBY Both OFFOV/THERM Both OFFDC/LF One ONOUTPUT MOD Both OFF

CauseAt any time the main relay is off (open), the ODEP indicator is alsoheld off. Any protective action which will result in amplifier shut-down will cause the ODEP indicator on the affected channel to beoff. The ODEP indicator will also be off when the amplifier is into“full ODEP” limiting. Under the initial conditions described, theconditions in the left column will only occur when there is a failurein one relay or relay control circuit, in the ODEP circuit itself, or ina thermal sensor for the ODEP circuit.

An ODEP indicator off coupled with one or both internal STBYindicators lit is most often caused by low line voltage. It may alsobe caused by placing a logical low on a RS (remote standby func-tion) connection to the PIP module. First, verify AC mains voltageand check the amplifier to ensure it is wired for the appropriateAC mains. The RS port from the PIP module is not likely to be atfault, but if an IQ-PIP is installed, it may be necessary to replace itwith a blank module (such as the PIP2-FXQ) for testing purposes.

Both ODEP indicators off coupled with both internal OV/THERMindicators lit is most often caused by high line voltage (>10% abovewhat the amplifier is wired for). It is extremely unlikely that thethermal switches in both amplifier channels will be activated. First,verify AC mains voltage and check the amplifier to ensure it iswired for the appropriate AC mains. If fans are running at full speed,a transformer thermal condition is probably being stimulated by afailed IC such as U707.

One ODEP indicator off coupled with one internal OV/THERM in-dicator lit will result from an open thermal switch in the toroid ofthe affected channel. Except for very early units with control mod-ule Q42930-0, fans should both be operating at high speed. Ifthey are, a thermal switch is in fact open. If fans are off or nearlyoff (and control module is Q43096-9 or later), the problem is morelikely a failed Q709 (Ch 1) or Q707 (Ch 2).

One ODEP indicator off coupled with IOC and DC/LF indicationsindicates a DC offset at the amplifier's output. The amplifier mayattempt to cycle if a small offset is being caused by a malfunction.This may not be the direct result of an output device failure. It mayrather be caused by a grossly maladjusted or faulty balance con-trol within the amplifier. It may also be caused by any number ofminor components failing in an unexpected manner. It could alsobe the result of an unbalanced ODEP circuit (±ODEP bias poten-tials unequal). If the DC/LF indication remains locked in, the OUT-PUT MOD Fault circuit may be activated, but on occasion the DC/LF circuit will trigger faster causing this indication. Observe theoutput with a scope to determine if cycling action is in fact occur-ring.


5-4 Maintenance

130446-1 Rev. A


5.4 Test ProceduresThe following test procedures are to be used to verifyoperation of this amplifier. DO NOT connect a load orinject a signal unless directed to do so by the proce-dure. These tests, though meant for verification andalignment of the amplifier, may also be very helpful introubleshooting. For best results, tests should be per-formed in order.

All tests assume that AC power is from a regulated 120VAC source. Test equipment includes an oscilloscope,a DMM, a signal generator, loads, and I.M.D. and T.H.D.noise test equipment.

WARNING! Most adjustments are made with the cov-ers removed. Prior to any AC power off testing, dis-charge all power supply capacitors. Also, use ex-treme caution when making internal adjustmentswhen the unit is powered.

Indicator ConditionODEP Both OFFSPI/IOC Both ONILOAD/ILIMIT Both OFFSTBY Both OFFOV/THERM Both OFFDC/LF Both ONOUTPUT MOD Both OFF

ODEP One OFFSPI/IOC Either OFF/ONILOAD/ILIMIT Either OFF/ONSTBY Both OFFOV/THERM Both OFFDC/LF Both OFFOUTPUT MOD One ON

ODEP Both OFFSPI/IOC Both OFFILOAD/ILIMIT Both OFFSTBY Both OFFOV/THERM Both OFFDC/LF Both OFFOUTPUT MOD Both OFF

CauseBoth ODEP indicators off coupled with both IOC and DC/LF indi-cations indicates a DC offset at both outputs. If possible, inquire ifthe user was operating the amplifier in a mono mode when thefailure occurred. If so, then it is likely that output stage damagehas occurred in both channels. If not, two unique problems mayhave occurred, or there may be an unexpected short on the ter-minator/current sense module. Other unexpected shorts may bepossible. Mechanical integrity should be carefully checked.

An ODEP indicator off coupled with one internal OUTPUT MODindicator lit may be accompanied with IOC and ILOAD/ILIMIT for theaffected channel. Such a fault is latching and keeps the high volt-age rails off. This type of fault is caused by conduction in both thepositive and negative half of the output stage simultaneously.Under normal conditions this cannot occur at levels much above100mW, assuming the amplifier is properly biased. A fault like thisis usually the result of a failed output device, or possibly a failedbias network. It may also be caused by operating the amplifier atextremely high levels with ultra-sonics.

Both ODEP indicators off with no other abnormal indication is al-most impossible unless both relays fail, or the Power Loss IC(U111A) circuit has failed.

5.4.1 Standard Initial ConditionsThe start of each step assumes all switches are pre-setto the following positions:

Dual Mono Switch: STEREO position.Sensitivity Switches: Both to 0.775V position.Compressor Switches: Both to OFF position.LOI Switches: Both to OFF position.VZ Mode Switches: Both to VZ position.Level Controls: Both up (clockwise) fully.

5.4.2 Equipment RequiredThe following is a list of standard equipment needed toperform all the tests listed in Section 2.3.3:

Line Voltage Variac: 5 kW or larger.Oscilloscope: 2 Channel, 10 MHz or better.Digital Multimeter: Various measurements.Watt Meter: For AC line draw.ACVM: Peak reading RMS calibrated (all AC linevoltage and amplifier output voltage checks).I.M.D. Analyzer: 60 Hz/7 kHz in 4:1 ratio, accurate to0.001% I.M.D.T.H.D. Analyzer: Accurate to 0.001%.Loads: 3000 W continuous at 1 ohm.

Maintenance 5-5



Type of Test Input Signal and Commentsor Adjustment Load Parameters

WARNING: Do not connect any load to the MA-5002VZ power amplifier during these testsuntil specifically instructed to do so.

Check for a delay of approximately 4 seconds fromthe time the power push button is pressed until theIOC indication clears and ODEP indicators come on.If the IOC fails to clear in one channel, check for pres-ence of rail voltages and for a DC offset. Also checkcircuit board LED for indication of a fault - DC/LF,Output Module, and OV/TSW. Turn unit off, discon-nect the power cord, discharge power supplies, andcheck for a failure in the output stage of the affectedchannel, or other applicable circuit area. If the fanslock in high speed after delay times out, check fancontrol components, ODEP output, and LM334Z de-vices on the output modules.

With the input level controls turned fully clockwise,the DC offset for both channels should be less than±15 millivolts. Note: There are no output offset adjust-ments for the MA-5002VZ. A small DC offset may in-dicate an ODEP failure. A large DC offset usually indi-cates a failure in the output stage, though such anoffset should have shut down the amplifier on a DC/LFI signal.

While there is no published specification on quies-cent power, it should be checked. A power draw withthe fans off or operating slowly will normally be lessthan 150 W (<1.5 A). If quiescent power greatly ex-ceeds expectation then turn the amplifier off immedi-ately and search for power supply or output failure. Ifquiescent draw exceeds expectation by a “small”amount check bias immediately.

Bias voltage is set while the amplifier is at room tem-perature. If the amplifier is hot from prior testing forrepair or other purposes, it should be set aside until ithas cooled before continuing with this check. Bias,once factory set, normally will not require adjustment.For channel 1: Measure the voltage at TP1 pin 2 withrespect to pin 4 (DO NOT measure from ground refer-ence). The bias voltage should equal .330VDC ± 10millivolts. If the bias voltage needs to be adjusted,adjust R505 on the channel 1 output assembly for thecorrect bias voltage. For channel 2: Measure the volt-age at TP2 pin 2 with respect to pin 4 (DO NOT mea-sure from ground reference). The bias voltage shouldequal .330VDC ± 10 millivolts. If the bias voltage needsto be adjusted, adjust R505 on the channel 2 outputassembly for the correct bias voltage.

1. Turn-on Delay No SignalNo Load

2. DC Output Offset No SignalNo Load

3. Quiescent Power No SignalNo Load

4. High Side Bias No SignalNo Load


5-6 Maintenance

130446-1 Rev. A


Bias voltage is set while the amplifier is at room tem-perature. If the amplifier is hot from prior testing forrepair or other purposes, it should be set aside until ithas cooled before continuing with this check. Bias,once factory set, normally will not require adjustment.For channel 1: Measure the voltage at TP1 pin 15 withrespect to pin 13 (DO NOT measure from ground ref-erence). The bias voltage should equal .330VDC ±10 millivolts. If the bias voltage needs to be adjusted,adjust R556 on the channel 1 output assembly for thecorrect bias voltage. For channel 2: Measure the volt-age at TP2 pin 15 with respect to pin 13 (DO NOTmeasure from ground reference). The bias voltageshould equal .330VDC ± 10 millivolts. If the bias volt-age needs to be adjusted, adjust R556 on the chan-nel 2 output assembly for the correct bias voltage.

ODEP Nulls are based on heatsink temperatures. Areference voltage is supplied at TP1/TP2 which is pro-portional to the heatsink temperature. For positiveODEP: Measure TP1/TP2 pin 18 with respect toground. Refer to the chart (Figure 5.1) below. If mea-sured voltage falls outside the listed range, the am-plifier is too hot or too cold. Now measure TP1/TP2pin 11 and adjust, if necessary, R182/R282 for the setvoltage on the chart, ±0.1 V. For negative ODEP: Mea-sure TP1/TP2 pin 17 with respect to ground. Refer tothe chart (Figure 5.1) below. If measured voltage fallsoutside the listed range, the amplifier is too hot or toocold. Now measure TP1/TP2 pin 9 and adjust, if nec-essary, R191/R291 for the set voltage on the chart,±0.1 V. Note that the negative ODEP set voltage is anegative voltage with respect to ground.

5. Low Side Bias No SignalNo Load

6. O.D.E.P Null No SignalNo Load

Figure 5.1 ODEP Set Voltage Chart


VoltageMeasured

ODEP SetVoltage

2.90 V2.91 V2.92 V2.93 V2.94 V2.95 V2.96 V2.97 V2.98 V2.99 V

12.96 V12.64 V12.72 V12.60 V12.48 V12.36 V12.24 V12.12 V12.00 V11.88 V

VoltageMeasured

ODEP SetVoltage

3.00 V3.01 V3.02 V3.03 V3.04 V3.05 V3.06 V3.07 V3.08 V3.09 V

11.76 V11.64 V11.52 V11.40 V11.28 V11.16 V11.04 V10.92 V10.80 V10.68 V

Maintenance 5-7



WARNING: Many of the following checks are done by connecting a resistive load to the output of theamplifier. Use caution and follow check-out procedures carefully to ensure correct results. Thesetests require a resistive load capable of over 3000 W continuous into as low as 1 ohm.

WARNING: The MA-5002VZ is capable of drawing in excess of 80 Amperes of current from 120VACMains when loaded to 2 ohms per channel and with both channels driven by a 1 kHz sine wave.

CAUTION: 30 A fuses should be replaced after completion of tests, as they will be stessed during highpower tests. Special 30 A test fuses may be used during testing if they are replaced with the stockfuses after the tests. 30 A fuse part number is A10285-30.

With the sensitivity switch in the high gain position(0.775V), insert a common mode 1-kHz 0 dBu squarewave into channel 1 (phono tip & ring shorted or XLRpins 2 and 3 shorted). At the output jacks measureless than 25 mV. If necessary adjust R105. Repeattest for channel 2, adjust R205 if necessary. This ad-justment is easiest when done with an oscilloscopeat the output and adjusting the square wave for a flatline. (Set scope for high vertical sensitivity.)

Set the sensitivity switches to the 26-dB position,check both level controls full clockwise. Insert a .775V1-kHz sine wave and measure 14.8V–16.1V at the out-put of each channel. Set sensitivity to the 0.775V po-sition and measure 95V–104V at the output of eachchannel. Set the sensitivity switches to 1.4V positionand measure 51.8V–57.2V at the output of each chan-nel.

Note: Always turn power to the amplifier off prior tochanging the position of the Stereo/Mono Switch. Withthe dual/mono switch in the bridge mono position, setthe channel two input level control to full CCW. Inserta .775 Vrms 1-kHz signal into channel one input. Thereshould be signal present on both channel outputs,equal in amplitude, with channel two 180 degrees outof polarity from channel one (see Figure 5.2). Chan-nel one input level control should control the outputlevel for both channels. Return the amplifier to stereooperation.

7. CMR Null 0.775V (0 dBu),1-kHz Sq. WaveNo Load

8. Sensitivity (Gain) 1-kHz Sine WaveNo Load

9. Bridge Mono 1kHz Sine WaveNo Load



5-8 Maintenance

130446-1 Rev. A


10. Parallel Mono 1-kHz Sine WaveNo Load

11. Current Sense Balance No SignalNo Load

12. Static Balance No SignalNo Load

13. Dynamic Balance 1-kHz Sine WaveNo Load

Note: Always turn power to the amplifier off prior tochanging the position of the Stereo/Mono Switch. Withthe dual/mono switch in the parallel mono position,insert a .775 Vrms 1-kHz signal into channel one. Thereshould be two signals with the same polarity present,equal in amplitude, at the outputs of channels oneand two. Both of these signals will be controlled bythe channel one input level control. Switch the stereo/mono switch to stereo. There should be signal presentonly on the channel one output.

Place the Stereo/Mono switch in the PARALLEL MONOposition. Measure VDC of the channel 1 + output withrespect to the channel 2 + output. Verify null of lessthan ±10 mVDC. If necessary adjust null via R2 cur-rent sense balance pot on the Main Module.

Place the VZ Mode switches in the VZ-ODEP position(see Figure 5.4). Measure ±VCC with respect toground for channel 1 (P852 & P851 on Control board).Values should be of equal magnitude and oppositepolarity. If magnitudes vary by more than 500mV, ad-just static balance pot R568 on the output module fornull (no difference in magnitude). Switch to VZ (AUTO)position and verify null is maintained. Re-adjust onlyif necessary. Repeat check for channel 2 (P854 & P853on Control board), adjust R568 if necessary.

With no load on the amplifier, increase the input toachieve 125.0 Vrms, ±.3 Vrms, at the output of thechannel under test. Measure TP1/TP2 pin 16 and ad-just R566 on the output module for 3.500 Vrms, ±.200Vrms.


Figure 5.2 Bridge MONO

Maintenance 5-9



With the amplifier powered from a variac, increaseAC mains line voltage to 12% above the line voltagefor which the amplifier is wired. The amplifier shouldtrip off at 10.5% to 11% above the line voltage forwhich it is wired. If it does not, then set line voltage to10.5% high and slowly adjust R780 on the controlmodule until the amplifier trips into protect mode. Ifadjustment is performed, retest new adjustment.

Place sensitivity switches in 26 dB position; check orplace LOI (EPS) switches to OFF (BYPASS) position.Insert a 1-kHz sine wave and adjust for 2.8 Vrms(1 W) output into 8 ohms. Adjust to 30 Hz then to20 Hz, level should remain constant. Switch LOI (EPS)to ON (ENABLE). Check output at 30 Hz at –2 dB ±0.1 dB. Adjust frequency to 20 Hz and measure out-put level at –11 dB ± 0.1 dB. Return LOI/ESP andsensitivity switches to initial condition (Section 5.4.1).

With each channel loaded to 8 ohms, insert a 1-kHzsine wave and increase level until the amplifier is wellinto clip. Place the compressor switches in SLOW po-sition and check for non-clipped output. Moveswitches to FAST position and again verify non-clippedoutput. Return switches to OFF position.

Place the Stereo/Mono switch in the PARALLEL MONOposition. Load each channel to 8 ohms separately,(loads must be precisely equal) and insert a 1 kHzsine wave. Adjust for 60 Vrms output. Measure VACof the channel 1 + output with respect to the channel2 + output. Verify null of less than 100 mVrms withsignal applied. If necessary adjust null via R4 parallelbalance pot on the Main Module. Make sure the Ste-reo/Mono switch is returned to STEREO upon testcompletion.

Factory set adjustment normally will not requirerecalibration. Perform this check as a verification,adjust only if the measurement is out of tolerance. Withchannel 1 loaded to 1 ohm, insert a 1 kHz sine waveand adjust for an output of 10.00 Vrms, ±20 mV. Mea-sure TP1 pin 1 with respect to ground. Value shouldbe 2.00 Vrms ±10 mV. If necessary adjust V/A cal potR759 on the current sense module. Repeat test forchannel 2 measuring TP2 pin 1; adjust R859 if neces-sary.


14. Over-voltage No SignalNo Load

15. LOI Sine Wave8-ohm Load

16. Compressor 1-kHz Sine Wave8-ohm Load

17. Parallel Balance 1-kHz Sine Wave8-ohm Load

18. Current Sense Cal. 1-kHz Sine Wave1-ohm Load


5-10 Maintenance

130446-1 Rev. A



Turn the amplifier on after being off at least 10 sec-onds. Observe that the ODEP lights come on afterabout 4 seconds. The SPI/IOC lights should go off (ifon during delay) at this time. Input a 1-kHz 2 Vrmssine wave into each channel and observe that the SPI/IOC lights are on bright. Turn down the input level toabout 0.5 Vrms and observe that the SPI/IOC lightsremain on, but dimly. Remove the input signal andload the amplifier to 8 ohms/Ch. Insert the 0.5 Vrmssignal again and note that the ILOAD/ILIMIT indicatorscome on green. Change the load to 1 ohm/Ch, switchto a square wave (20% Duty Cycle), and increase in-put level to 2 Vrms. Note that the ILOAD/ILIMIT indicatorsturn red. This check also constitutes the Current LimitCheck.

With an 8-ohm load on each channel, insert a 10-kHzsquare wave and adjust amplitude to produce anoutput 10V below clipping (see Figure 5.3). Observea 30V/µS (or higher) slew rate. The output waveformshould be stable with no ringing or over-shoot.

Insert a 5Vpp 4-Hz square wave with an 8-ohm loadon the output. The protection relay should cycle.

19. LED Check, 1-kHz Sine/Sq WaveCurrent Limit Check Various Loads

20. 10 kHz Square Wave 10-kHz Sq. WaveSlew Rate Test 8 ohm Load

21. DC/LF Protect 4-Hz Sq. Wave8-ohm Load

Figure 5.3 10-kHz Square Wave

Maintenance 5-11




Note: Operation with a sine wave into a low imped-ance load, when operating at AC voltages of less than200VAC, will cause the 30 A fuses to blow after 30 to60 seconds. 30 A Fuse = Part Number A10285-30.

AC Mains of 120 VAC, 60 Hz; or 230/240 VAC, 50 Hz:8-ohm Load: Minimum voltage is 102.0 Vrms(1,300 W) with <0.1% THD.

4-ohm Load: Minimum voltage is 89.1 Vrms(1,985 W) with <0.1% THD.


AC Mains of 100-220 VAC, 50Hz:8-ohm Load: Minimum voltage is 100.0 Vrms(1,250 W) with <0.1% THD.



For these tests, the cooling fan blade must be stopped.To stop the fans, turn off and unplug the amplifier. Liftthe fan wire connector from P729/P730 on the controlmodule. Turn the amplifier back on and perform thesetests. At the end of these tests, turn the amplifier off,unplug it, and return the fan wires to the appropriateposition (P729 or P730).

Place the VZ mode switches in the AUTO position (seeFigure 5.4; remove top filter to access switches). Witha 2-ohm load per channel and output voltage of 60Vrms 60 Hz to both channels, allow the heatsinks toheat up until the ODEP protection circuit starts to limitthe output signal (this should take a few minutes). Awaveform like that shown in Figure 5.5 should be ob-served. Note: In VZ AUTO mode the flattened portionof the wave will probably not have the “clean” ap-pearance of Figure 5.5, but should still resemble it.Check to see that the IOC LED is lit and that the ODEPLED dims and extinguishes when ODEP is activated.While ODEP limiting is taking place, switch the VZmode switches to the VZ-ODEP position and verifythat the amplifier locks into low voltage mode (theODEP waveform should appear much more “clean”).

22. 1 kHz Power + THD 1-kHz Sine WaveVarious Loads

23. Functional 60-Hz Sine WaveODEP & VZ-ODEP 2-ohm Loadoperation


5-12 Maintenance

130446-1 Rev. A



Next configure the amp for parallel mono operation.With the input signal now present on channel one only,load channel one output with 8 ohms and channeltwo with 2 ohms. Observe that channel two ODEPprotection circuit is limiting both channel one andchannel two outputs. Next load channel one with 2ohms and channel two with 8 ohms. Observe thatchannel one ODEP protection circuit is limiting bothchannel one and channel two outputs.

Return the cooling fan blade to normal operation af-ter these tests have been completed, and allow a fewminutes for the amplifier to cool with no signal input.Return all controls to initial conditions per Section5.4.1.

Correct operation of the ODEP circuit is dependentupon correct ODEP null settings (Step 6).

Place the sensitivity switches in the 26 dB position.Use a 60-Hz/7-kHz (standard SMPTE IM signal) inputsignal summed in a 4:1 ratio. Set the 60-Hz portionfor 73.8 Vrms at the output of the channel under test.This is your 0 dB reference. Measure the I.M. distor-tion. Check in –5 dB (power) steps until –35 dB isreached (range is 1,065 W down to 0.34 W). Read-ings should be less than .05% at each level.

24. Intermodulation I.M. Signal SourceDistortion (I.M.D.) 8-ohm Load

Figure 5.5 ODEP Protection

ENABLECH2

l 0

30

27

24

1815

9

6

3

0

LEVEL

21

12

VZ-ODEPLOCK LOWVZ (AUTO)

VZ (AUTO)*

VZ (AUTO)*VZ (AUTO)LOCK LOWVZ-ODEP

CH 1 VZ MODE SWITCH CH 2 VZ MODE SWITCH

*On Original Control ModuleQ42930-0 this was theLOCK HIGH position.

Figure 5.4 VZ Mode Switch Locations

Maintenance 5-13




Make sure the sensitivity switches are in the 26-dBposition and the level controls are fully clockwise. Ter-minate the input with a 600-ohm load. Using a 20 Hz–20 kHz bandpass filter, measure the noise on the out-put of the channel under test. Noise should be lessthan 574 µVrms (105 dB down from 1300 watts into 8ohms).

Make sure the sensitivity switches are set in the26-dB position. Load each channel to 8 ohms. Inserta 20-kHz sine wave into channel 1 and adjust for 45Vrms output. Terminate channel 2 input with 600 ohms.Measure less than 80 mVrms at the output of channel2. (Greater than 55 dB down at 20 kHz)

Move the input signal from channel 1 to channel 2and the 600-ohm termination from channel 2 to chan-nel 1. Ensure there is 45 Vrms at the output of chan-nel 2. Measure less than 80 mVrms at the output ofchannel 1.

Note: VZ-ODEP mode was checked during the ODEPtest, Step 23. I.M.D. and 1-kHz power checks ad-equately tested the VZ (AUTO) mode. LOCK HIGH (ifpresent) was checked adequately in the static bal-ance adjustment check, Step 12. Place the VZ ModeSwitches in LOCK LOW (see Figure 5.4). With an8-ohm load on each channel, insert a 1-kHz sine waveinto each channel. Clipping should occur at approxi-mately 36 Vrms (410 W).

At the completion of testing, replace the 30 A fuses (iftesting was done at 100–120VAC), and set all switchesper customer request. If none are specified by thecustomer, the following are standard factory settingsfor original shipment:

Dual Mono Switch: STEREO position.Sensitivity Switches: Both to 1.4V position.Compressor Switches: Both to FAST position.LOI Switches: Both to ON position.VZ Mode Switches: Both to VZ–ODEP position.Level Controls: Both down (counter-clockwise) fully.

In most applications, VZ–ODEP is the VZ Mode to usefor best thermal performance.

25. Noise No SignalNo Load

26. Crosstalk Check 20-kHz Sine Wave8-ohm Load

27. VZ Modes 1-kHz Sine Wave8-ohm Load

Post-testing Procedure:


5-14 Maintenance

130446-1 Rev. A



Parts 6-1



6.1 General InformationReplacement parts for this Crown amplifier can be or-dered from the Crown parts department.

PART PRICES AND AVAILABILITY ARE SUBJECTTO CHANGE WITHOUT NOTICE.

6.2 Ordering and Receiving PartsWhen ordering parts, be sure to give the product model,and include a description and part number from theparts listing. Price quotes are available on request.

6.2.1 TermsNormal terms are prepaid. Net-30 Days only applies tothose having pre-established accounts with Crown. TheCrown Parts Department does accept Visa or MasterCard. If prepaying, the order must be packed andweighed before a total bill can be established, afterwhich an amount due will be issued and shipment madeupon receipt of payment. New parts returned for creditare subject to a restocking fee, and authorization fromthe Crown Parts Department must be obtained beforereturning parts for credit.

6.2.2 ShipmentShipment will normally be made via UPS, or best othermethod unless you specify otherwise. Shipments aremade to and from Elkhart, Indiana USA, only. Estab-lished accounts with Crown will receive shipment freightprepaid and will be billed. All others will receive ship-ment on a C.O.D. or prepayment (check or credit card)basis.

6 Parts

Crown Customer ServiceTechnical Support Group

Factory ServiceParts Department

Mailing Address: P.O. Box 1000, Elkhart IN 46515Shipping Address: Plant 2 S. W.

1718 W. Mishawaka Rd., Elkhart IN 46517Phone: (219) 294-8200

Toll Free: (800) 342-6939Fax: (219) 294-8301

http://www.crownaudio.com


6-2 Parts

130446-1 Rev. A



MA-5002VZ Service Manual130446-1 Rev A

Exploded View Parts 7-1©2000 Crown International, Inc.

7.1 General InformationThis chapter includes a mechanical part list for thisproduct. All serviceable parts and assemblies will havea Crown Part Number (CPN) listed in this chapter.The parts listed are current as of the date printed.Crown reserves the right to modify and improve itsproducts for the benefit of its customers.

7 Exploded View Parts

MA-5002VZ Service Manual 130446-1 Rev A

7-2 Exploded View Parts ©2000 Crown International, Inc.

Figure 7.1 Main Chassis Exploded View



7.1 Main Chassis Assembly

NotesItem # QTY Part Number Description

1 1 --- Front Chassis Assembly See Section 7.2

2 1 --- Transformer Assembly See Section 7.6

3 1 F12701-3 Chassis

4 1 --- Ch 1 Capacitor Assembly See Section 7.7

5 1 F12567J7 Bottom Cover

6 1 --- Terminator Assembly See Section 7.9

7 1 --- Output Assembly See Section 7.12

8 1 --- Back Panel See Section 7.4

9 1 F12302J9 Output Cover

10 1 102745-1 PIP2-FXQ

11 1 --- Main Board Tray Assembly See Section 7.11

12 1 F12176J7 Top Cover

13 1 --- Chassis Divider Assembly See Section 7.5

14 1 --- Ch 2 Capacitor Assembly See Section 7.8



Figure 7.2 Front Chassis Assembly



7.2 Front Chassis Assembly


2 4 A10089-11032 Screw, 10-32 X 2

3 4 A10094-8 Washer, #10 Int. Tooth

4 4 A10094-5 Washer, #8 Int. Tooth

5 4 C 8874-7 Screw, 8-18 X .375 Sht mtl

6 3 A10092-10607 Screw, 6-32 X .437 Socket

7 1 --- Transformer Bracket See Transformer Assembly, Section 7.6

8 2 C 8507-3 Screw, 8-32 X 1 Flat Hd

9 1 F12888-8 Front Panel

10 1 128304-1 MA-5002VZ Lexan Overlay

11 2 C 8776J3 Handle

12 2 D 6265-9 Knob

13 2 C 6005-0 Set Screw, 6-32 X .18

14 2 --- Nut Part of item 23

15 2 --- Washer Part of item 23

16 7 D 7937-2 LED Collar

17 1 D 7872-1 Pushbutton

18 1 D 4108-3 Pushbutton Collar

19 5 D 7696-4 Foam Filter

20 20 B 5796-6 Velcro .5" x .25"

21 4 C 7965-4 Screw, 8-32 X .37 Flat Hd

22 1 D 7791J2 Grille Extrusion

23 2 C 7280-8 5K ohm Level Pots Includes hardware items 14 and 15

24 2 D 7792J0 Panel Cap

25 2 D 7793J8 End Cap




Figure 7.3 Middle Chassis Assembly



7.3 Middle Chassis Assembly



2 1 --- Divider Assembly See Section 7.5

3 2 D 7927-3 Capacitor Holder, Inner

4 2 D 7928-1 Capacitor Holder, Outer

5 1 M46664-5 Ch 2 Bi-Level Switch Assby See Section 7.8

6 2 D 7870-5 Valox Washer

7 6 A10100-10 Flat Washer, #8

8 6 A10094-6 Lock Washer, #8 Int Star

9 2 A10089-70820 Screw, 8-32 X 1.25

10 1 M46665-2 Ch 1 Bi-Level Switch Assby See Section 7.7

11 2 A10089-10808 Screw, 8-32 X .5

12 4 D 7871-3 Valox Spacer

13 2 D 7818-4 Output Slide Guide

14 1 --- PIP Terminator Assembly See Section 7.9

15 1 --- Ch 1 Output Assembly See Section 7.12 (Ch 1 & 2 are identical)

16 2 A10089-10612 Screw, 6-32 X .75

17 2 A10094-4 Lock Washer, #6 Int Star

18 2 A10100-4 Flat Washer, #6

19 1 --- Ch 2 Output Assembly See Section 7.12 (Ch 1 & 2 are identical)

20 13 C 8874-7 Screw, 8-18 X .375 sht mtl

21 15 A10094-5 Lock Washer, #8 Int Str Blk

22 15 F12567J7 Bottom Cover

23 4 A10109-70604 Screw , 6-32 X .25 Black

24 2 A10089-70844 Screw, 8-32 X 2.75

25 2 A10100-12 Washer, 3/16 X 9/16 X 1/16



Figure 7.4 Rear Chassis Assembly



7.4 Rear Chassis Assembly

1 1 F12176J7 Top Cover

2 - --- Main Board Tray Assembly See Section 7.11

3 1 128302-1 Back Panel

4 1 F12302J9 Box Shield Output post protective cover

5 1 102745-1 PIP2-FXQ

6 4 C 8874-7 Screw, 8-18 X .375 Sht Mtl

7 13 A10089-70806 Screw, 8-32 X .375

8 17 A10094-5 Lock Washer, #8 Int Str Blk




Figure 7.5 Chassis Divider (Fan) Assembly

AIR FLOW

1

5

2

3

4



7.5 Chassis Divider (Fan) Assembly

1 1 100111-1 Divider Plate

2 2 C 7858-1 Fan

3 1 D 7883-8 Transformer Low Voltage Transformer

4 1 C 9069-3 Bushing, Universal 0.875

5 8 A10106-70806 Screw, #8 X .37 Hex Washer Head

Item # QTY Part Number Description Notes



Figure 7.6 Transformer Assembly

1

14

15

10

7

2

4

3

5

66

89

16

11

12

13



7.6 Transformer Assembly

1 4 C10332-2 Bridge Rectifier, 50A EDI

2 1 Control Module See Section 8.

3 1 Q42929-2 Display Module See Section 8.

4 3 C 8852-3 0.5" PC Board Support

5 1 F12813-6 XFMR/Sub-front Bracket

6 2 D 9019-7 Main Power Toroid XFMR

7 2 C 8919-0 0.5" Steel Bolt

8 2 A10095-7 0.5" Ext. Lockwasher

9 2 A10102-21 0.5" Hex Nut

10 1 C10180-5 DPST 6A Pushbutton Switch

11 2 C 5961-5 4-40 X .375 Taptite

12 7 A10094-4 #6 Int. Star Washer

13 7 A10086-10608 6-32x.5 Machine Screw

14 4 A10098-3 #8 HDS-4 Saftey Washer

15 4 A10102-6 8x32 Hex Nut

16 2 A10100-25 0.5" Plain Steel Washer




Figure 7.7 Channel 1 Bi-Level Switch Assembly



7.7 Ch 1 Bi-Level Switch Assembly (M46665-2)

1 2 D 7882-0 15000µF Capacitor C810, C812

2 1 P10357-5 Insulator: Ch 1 & 2 #1

3 1 M21070-4 Plate: Ch 1 -Vcc #1

4 1 D 7821-8 Insulator: Ch 1 #2

5 3 C 6541-4 Torque Spreader

6 3 C 9927-2 MOSFETs Q810, Q811, Q812

7 3 A11397-003 Lead Insulation Tube

8 3 C 8341-7 Ferrite Bead FB1, FB2, FB3

9 1 M21071-2 Plate: Ch 1 FET #2

10 - --- Wires

11 1 D 7825-9 Insulator: Ch 1 & 2 #3

12 1 M21072-0 Plate: Ch 1 Diode #3

13 1 D 7822-6 Insulator: Ch 1 #4

14 1 M21073-8 Plate: Ch 1 +Vcc #4

15 1 A10086-11008 Screw, 10-32 X .5

16 1 D 2934-4 Solder Lug

17 11 A10094-4 Lock Washer, #6

18 9 A10086-10604 Screw, 6-32 X .25

19 1 A10086-11006 Screw, 10-32 X .375

20 1 A10086-11005 Screw, 10-32 X .315

21 2 C 8855-6 Dual Diode D810, D811

22 2 A10102-5 Hex Nut, 6-32

23 1 H43479-7 Header (with wires)

24 1 D 7843-2 Switch Board Ch 1 (Ch 1 half of blank part D 7843-2)

25 1 D 7880-4 Insulator: Ch 1 & 2 #5

26 1 A10086-11009 Screw, 10-32 X .562

27 4 A10094-8 Lock Washer, #10

28 6 A10101-26 Nylon Washer

NotesDescriptionItem # QTY Part Number



Figure 7.8 Channel 2 Bi-Level Switch Assembly



7.8 Ch 2 Bi-Level Switch Assembly (M46664-5)

NotesDescriptionItem # QTY Part Number

1 2 D 7882-0 15000µF Capacitor C800, C802

2 1 P10357-5 Insulator: Ch 1 & 2 #1

3 1 M21074-6 Plate: Ch 2 -Vcc #1

4 1 D 7824-2 Insulator: Ch 2 #2

5 3 C 6541-4 Torque Spreader

6 3 C 9927-2 MOSFETs Q800, Q801, Q802

7 3 A11397-003 Lead Insulation Tube

8 3 C 8341-7 Ferrite Bead FB4, FB5, FB6

9 1 M21075-3 Plate: Ch 2 FET #2

10 - --- Wires

11 1 D 7825-9 Insulator: Ch 1 & 2 #3

12 1 M21076-1 Plate: Ch 2 Diode #3

13 1 D 7820-0 Insulator: Ch 2 #4

14 1 M21077-9 Plate: Ch 2 +Vcc #4

15 1 A10086-11008 Screw, 10-32 X .5

16 1 D 2934-4 Solder Lug

17 11 A10094-4 Lock Washer, #6

18 9 A10086-10604 Screw, 6-32 X .25

19 1 A10086-11006 Screw, 10-32 X .375

20 1 A10086-11005 Screw, 10-32 X .312

21 2 C 8855-6 Dual Diode D800, D801

22 2 A10102-5 Hex Nut, 6-32

23 1 H43479-7 Header (with wires)

24 1 D 7843-2 Switch Board Ch 2 (Ch 2 half of blank part D 7843-2)

25 1 D 7880-4 Insulator: Ch 1 & 2 #5

26 1 A10086-11009 Screw, 10-32 X .562

27 4 A10094-8 Lock Washer, #10

28 8 A10101-26 Nylon Washer



Figure 7.9 PIP Terminator Shelf Assembly



7.9 PIP Terminator Shelf Assembly


1 3 A10086-10604 6-32-.25 Machine Screw Phillips, round-head


3 1 --- Current Sense Module See Section 8

4 1 C 7705-4 Cable Clamp

5 1 --- Current Sense Module See Section 8

6 3 C 8823-4 0.125” PC Board Support

7 2 D 5903-6 8-32x.5 Screw Phillips, flat-head, taptite

8 1 F11160-3 Strain Relief For Power Cord D 7890-3

9 1 D 7890-3 Power Cord 30A 10/3 TT-30P Plug (No. America)

10 1 A10111-10806 #8x.375 Sheetmetal Screw Pan-head

11 1 A10095-2 #8 Ext. Star Washer

12 1 D 7817-6 Center Output Slide Guide

13 1 A10109-7064 6-20x.25 Screw Phillips, pan-head, black

14 1 F12699-9 Terminator/PIP Shelf Bracket

15 1 H43430-0 Output Flex Bar Ch 1 Includes Insulating Sleeve1 H43431-8 Output Flex Bar Ch 2 Includes Insulating Sleeve

16 1 --- Line Filter PWA See Section 8 (Export Only)



Figure 7.10 PIP Terminator Shelf Assembly, View "A"

7.10 PIP Terminator Shelf Assembly, View "A"(USA Units only)


1 16 C 8835-8 .25-32 Nut

2 12 A10094-9 Lockwasher, .25 Int. Star

3 4 M21078-7 Terminator Bar

4 4 D 7924-0 Bushing, Steel

5 1 D 7816-8 Terminator Panel

6 8 C 8794-7 Un-insulated Banana Jack

7 4 A10170-12516 .25-20x1 Machine Screw Output, slot hex-washer head



Figure 7.11 Main Module Tray Assembly

7.11 Main Board Tray Assembly


1 1 100110-1 Main Board Tray

2 1 See Section 8 Main Module See Section 8.


4 6 A10086-10604 6-32x.25 Machine Screw Phillips, round-head



Figure 7.12 Output Assembly



7.12 Output Assembly(Channels 1 & 2 Identical)


1 8 C 8187-4 NPN Outputs,8 C 8188-2 PNP Outputs,

2 1 F12154-5 Heatsink

3 1 M21188-4 Flex Bar Fastener

4 1 --- Negative Emitter Module See Section 8.

5 1 --- Negative Output Module See Section 8.

6 1 D 7922-4 Insulator

7 4 A10224-9 Rubber Grommets

8 1 --- Positive Output Module See Section 8.

9 2 C 8789-7 Flex Bar Spacers

10 1 --- Positive Emitter Module See Section 8.

11 2 D 7870-5 Valox Washer

12 3 A10100-16 Washer, 7/16OD X ,203ID

13 2 A10098-4 Belleville Washer, #10

14 2 A10086-10810 Screw, 8-32 X .62

15 3 A10094-6 Lock Washer, #8 Int. Star

16 1 A10089-10612 Screw, 6-32 X .75

17 32 A10110-10606 Screw, 6-32 X .375

18 1 A10089-10808 Screw, 8-32 X .5

19 1 A10089-70820 Screw, 8-32 X 1.25

20 4 A10086-10406 Screw, 4-40 X .37

21 4 A10098-1 Washer, .394OD X .126ID

22 6 A10086-10604 Screw, 6-32 X .25

23 4 A10094-4 Washer, #6 Int Star

24 4 C 6541-4 Predriver Torque Spreader

25 2 C 5453A1 PNP, 2SA1006BR2 C 6436-7 NPN, 2SC2336BR

26 2 C10223-3 PNP, MJL1302A2 C10224-1 NPN, MJL3281A

27 1 D 7871-3 Valox Spacer



Figure 7.13 Wiring Diagram #1



Interconnect Cables

J2A D 9236-7 20 Wire Ribbon Cable PIP2

J2B D 9235-9 18 Wire Ribbon Cable PIP2

J35 D 7886-1 16 Wire Ribbon Cable Main to Control to Display

J500 D 7889-5 16 Wire Ribbon Cable Main to Ch 1 Output P500 (top)

J501 D 7885-3 16 Wire Ribbon Cable Main to Ch 1 Output P501 (bottom)

J600 D 7885-3 16 Wire Ribbon Cable Main to Ch 2 Output P500 (bottom)

J601 D 7964-6 16 Wire Ribbon Cable Main to Ch 2 Output P501 (top)

J700 D 7887-9 16 Wire Ribbon Cable Main to Current Sense

J732 J832 D 7888-7 16 Wire Ribbon Cable Main to ControlD 8542-9 16 Wire Ribbon Cable Main to Control, Part of Control Mod.

J733 J833 H43479-7 Bi-Level Control Wires Control to Bi-Level Switches

R120 R220 H43551-3 Level Controls With Wires Also includes hardware

NotesDesignation Part Number Description

Module and Schematic Information 8-1



8.1 General Information

The schematics referenced and provided are repre-sentative only. There may be slight variations betweenamplifier to amplifier. These schematics are intendedto be used for troubleshooting purposes only.

Note on circuit board designations: Crown circuit boardsare referenced with a PWA and/or PWB part number.PWA stands for Printed Wire Assembly. This is the com-pleted circuit board with all components assembled.PWB stands for Printed Wire Board. This is the circuitboard only, without components.

8.2 Modules

8.2.1 Main PWA

125903-4Main PWA on 125902-4 PWB.

8.2.2 Positive Output PWA: (left and right are identical)

Q43293-2Positive Output PWA on D8526-2 PWB.

8.2.3 Negative Output PWA: (left and right are identical)

Q43294-0Negative Output PWA on D8527-0 PWB.

8.2.4 Positive Emitter PWA: (left and right are identical)

Q42935-9Positive Emitter PWA on P10336-9 PWB.

8.2.5 Negative Emitter PWA: (left and right are identical)

Q42934-2Negative Emitter PWA on P10342-7 PWB.

8.2.6 Control PWA

127488-2Control PWA on 127917-1 PWB.

8.2.7 Display PWA

Q42929-2Display PWA on D7845-7 PWB.

8.2.8 Current Sense PWA:

102397-2Current Sense PWA on 102395-2 PWB.

8.2.9 Line Filter PWA (CE Models Only):

128273-2Line Filter PWA on 128272-2 PWB.

8.3 Schematic Diagrams:

8.3.1 Main PWA125901

8.3.2 Positive Output PWAJ0488-7

8.3.3 Negative Output PWAJ0488-7

8.3.4 Positive Emitter PWAJ0488-7

8.3.5 Negative Emitter PWAJ0488-7

8.3.6 Control PWA128112-2

8.3.7 Display PWAJ0491-1

8.3.8 Terminator PWA102396

8 Module and SchematicInformation

8.3.9 Line Filter PWA128273-2


8-2 Module and Schematic Information

130446-1 Rev. A



Module Parts 9-1


©2000 Crown International, Inc

9 Module Parts

9.1 General InformationThis chapter includes electrical parts lists for this prod-uct. All serviceable parts and assemblies will have aCrown Part Number (CPN) listed in this chapter. Theparts listed are current as of the date printed. Crownreserves the right to modify and improve its productsfor the benefit of its customers. Please note: where ref-erence designations are listed as “installed on next as-sembly,” the CPN (Crown Part Number) for the associ-ated part may be found in Section 7, Exploded ViewParts.

102397-2125903-4127488-2128273-2Q42929-2Q42934-2Q42935-9Q43293-2Q43294-0


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9-16 Module Parts

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9-26 Module Parts

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MA-5002VZ Service Manual130446-1 Rev. A

©2000 Crown International, Inc. Module Parts 9-29

125903-4 PWA Component Map(Component Side)

MA-5002VZ Service Manual 130446-1 Rev. A

©2000 Crown International, Inc.9-30 Module Parts

This Page Intentionally Left Blank

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9-34 Module Parts

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9-36 Module Parts

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9-38 Module Parts

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127488-2 PWA Component Map(Component Side)

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Q42929-2 PWA Component Map(Component Side)

Module Parts 9-51



Capacitors

C513 0.022 µfd C 5671-0

C521 0.022 µfd C 5671-0

Diodes

D508 MR822 C 8383-9

D509 MR822 C 8383-9

Resistors

R523 0.33 ohm 5 W C 8787-1

R525 0.33 ohm 5 W C 8787-1

R527 0.33 ohm 5 W C 8787-1

R529 12 ohm 12 W A10266-1204

R535 12 ohm 12 W A10266-1204

R537 0.33 ohm 5 W C 8787-1

R539 0.33 ohm 5 W C 8787-1

R541 0.33 ohm 5 W C 8787-1

R581 0.33 ohm 5 W C 8787-1

R583 0.33 ohm 5 W C 8787-1

Q42934-2 Negative Emitter PWA

CircuitDesignation

ComponentDescription

PartNumber

Applicability& Notes

PWB: P10342-7, Schematic: J0488-7


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PWA Q42934-2 Component Map (Component Side)

Module Parts 9-53



Q42935-9 Positive Emitter PWA

CircuitDesignation

ComponentDescription

PartNumber

Applicability& Notes

PWB: P10336-9, Schematic: J0488-7

Capacitors

C512 0.022 µfd C 5671-0

C520 0.022 µfd C 5671-0

Diodes

D506 MR822 C 8383-9

D507 MR822 C 8383-9

Resistors

R522 0.33 ohm 5W C 8787-1

R524 0.33 ohm 5 W C 8787-1

R526 0.33 ohm 5 W C 8787-1

R528 12 ohm 12 W A10266-1204

R534 12 ohm 12 W A10266-1204

R536 0.33 ohm 5 W C 8787-1

R538 0.33 ohm 5 W C 8787-1

R540 0.33 ohm 5W C 8787-1

R580 0.33 ohm 5 W C 8787-1

R582 0.33 ohm 5 W C 8787-1


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Schematics 10-1



10 Schematics

102396125901128112128273J0488-7J0491-1

The schematics referenced and provided are repre-sentative only. There may be slight variations betweenamplifier to amplifier. These schematics are intendedto be used for troubleshooting purposes only.

Read This

Click the blue schematic numbers to open separate PDF files for schematics. This allows you to have both the schematic and the service manual files open for reference.


10-2 Schematics

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MA-5002VZ Service Manual

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